Inspection robot having replaceable sensor sled portions

ABSTRACT

Systems and methods for an inspection robot having replaceable sensor sled portions are disclosed. An example system may include: an inspection robot including a plurality of payloads; a plurality of arms, each of the plurality of arms pivotally mounted to one of the plurality of payloads; and a plurality of sleds, each sled mounted to one of the plurality of arms. At least one of the plurality of sleds includes an upper portion coupled to a replaceable lower portion, where the replaceable lower portion includes a portion of a delay line for a sensor of the inspection robot.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and is a continuation of U.S.patent application Ser. No. 15/988,969, filed May 24, 2018, and entitled“INSPECTION ROBOT HAVING REPLACEABLE SENSOR SLED PORTIONS”.

U.S. patent application Ser. No. 15/988,969 claims the benefit ofpriority to U.S. Provisional Patent Application Ser. No. 62/596,737,filed Dec. 8, 2017, and entitled “METHOD AND APPARATUS TO INSPECT ASURFACE UTILIZING REAL-TIME POSITION INFORMATION”.

U.S. patent application Ser. No. 15/988,969 is also a continuation ofU.S. patent application Ser. No. 15/853,391, filed Dec. 22, 2017,entitled “INSPECTION ROBOT”.

U.S. patent application Ser. No. 15/853,391 claims the benefit ofpriority to the following U.S. Provisional Patent Applications: Ser. No.62/438,788, filed Dec. 23, 2016, and entitled “STRUCTURE TRAVERSINGROBOT WITH INSPECTION FUNCTIONALITY”; and Ser. No. 62/596,737, filedDec. 8, 2017, and entitled “METHOD AND APPARATUS TO INSPECT A SURFACEUTILIZING REAL-TIME POSITION INFORMATION”.

Each of the foregoing applications is incorporated herein by referencein its entirety.

BACKGROUND

The present disclosure relates to robotic inspection and treatment ofindustrial surfaces.

SUMMARY

Previously known inspection and treatment systems for industrialsurfaces suffer from a number of drawbacks. Industrial surfaces areoften required to be inspected to determine whether a pipe wall, tanksurface, or other industrial surface feature has suffered fromcorrosion, degradation, loss of a coating, damage, wall thinning orwear, or other undesirable aspects. Industrial surfaces are oftenpresent within a hazardous location—for example in an environment withheavy operating equipment, operating at high temperatures, in a confinedenvironment, at a high elevation, in the presence of high voltageelectricity, in the presence of toxic or noxious gases, in the presenceof corrosive liquids, and/or in the presence of operating equipment thatis dangerous to personnel. Accordingly, presently known systems requirethat a system be shutdown, that a system be operated at a reducedcapacity, that stringent safety procedures be followed (e.g.,lockout/tagout, confined space entry procedures, harnessing, etc.),and/or that personnel are exposed to hazards even if proper proceduresare followed. Additionally, the inconvenience, hazards, and/or confinedspaces of personnel entry into inspection areas can result ininspections that are incomplete, of low resolution, that lack systematiccoverage of the inspected area, and/or that are prone to human error andjudgement in determining whether an area has been properly inspected.

In embodiments, a system may comprise an inspection robot comprising aplurality of payloads; a plurality of arms, wherein each of theplurality of arms is pivotally mounted to one of the plurality ofpayloads; a plurality of sleds, wherein each sled is mounted to one ofthe plurality of arms, wherein at least one of the plurality of sledscomprises an upper portion coupled to a replaceable lower portion, thereplaceable lower portion having a bottom surface shaped to accommodatean inspection surface; and an inspection sensor coupled to the upperportion of the one of the plurality of sleds such that the sensor isoperationally couplable to the inspection surface. In embodiments, thesystem may further comprise, wherein each of the plurality of sledscomprises a corresponding upper portion and replaceable lower portion,each replaceable lower portion having a bottom surface shaped toaccommodate the inspection surface; and a plurality of sensors, theplurality of sensors comprising the inspection sensor, and wherein eachof the plurality of sensors is coupled to one of the upper portions ofone of the plurality of sleds such that each of the plurality of sensorsis operationally coupleable to the inspection surface. A means may beprovided for configuring the inspection robot to perform an inspectionon the inspection surface at a selected horizontal resolution. A meansmay be provided for configuring the inspection robot, furthercomprising, each of the payloads comprising at least two of theplurality of arms such that the each of the corresponding sleds mountedto the at least two of the plurality of arms are horizontallydistributed. The plurality of sleds may be horizontally distributed onthe inspection surface at selected horizontal positions. The selectedhorizontal positions may comprise an inspection distance between twohorizontally adjacent sleds of the plurality of sleds that is notgreater than a selected horizontal resolution. One of the upper portionand the replaceable lower portion may comprise a plurality of engagementkeys, and wherein the other one of the upper portion and the replaceablelower portion comprise a plurality of engagement slots. The replaceablelower portion may define an aperture, and wherein the inspection sensoris operationally couplable to the inspection surface through theaperture.

In embodiments, a method may comprise determining a surface feature ofan inspection surface; selecting one of a multiplicity of replaceablelower portions of an inspection sled in response to the surface feature;and coupling the selected one of the multiplicity of replaceable lowerportions to an upper portion of the inspection sled, thereby forming acompleted inspection sled. In embodiments, the selecting the one of themultiplicity of replaceable lower portions may comprise selecting alower portion having at least one feature selected from the featuresconsisting of: a selected bottom surface shape; a selected ramp angle; aselected ramp total height value; a selected distance between a sensorcoupled to the upper portion and the inspection surface; and a selectedmaterial of the replaceable lower portion. The coupling the selected oneof the multiplicity of replaceable lower portions to an upper portionmay comprise twisting the replaceable lower portion into a coupledposition with the upper portion. The selecting may comprisemanufacturing the selected one of the replaceable lower portions afterthe determining the surface feature of the inspection surface.

In embodiments, a method may comprise providing an inspection robotcomprising a plurality of payloads and a plurality of arms, wherein eachof the plurality of arms is pivotally mounted to one of the plurality ofpayloads; and a plurality of sleds, wherein each sled is mounted to oneof the plurality of arms, and wherein each of the plurality of sledscomprises an upper portion coupled to a replaceable lower portion, eachreplaceable lower portion having a bottom surface that engages aninspection surface; removing one of the replaceable lower portions ofone of the plurality of sleds; and replacing the one of the replaceablelower portions of the one of the plurality of sleds. In embodiments, themethod may further comprise determining that the bottom surface of oneof the replaceable lower portions is damaged, and wherein the removingcomprises removing the damaged one of the replaceable lower portions.Manufacturing a new replaceable lower portion may use a 3-D printingoperation, and wherein the replacing comprises using the new replaceablelower portion. The replacing may comprises changing at least one featureof the replaceable lower portion selected from the features consistingof: a bottom surface shape; a ramp angle; a ramp total height value; adistance between a sensor coupled to the upper portion and theinspection surface; and a selected material of the replaceable lowerportion. The method may further comprise coupling an inspection sensorto a corresponding upper portion for the removed replaceable lowerportion, and wherein the removing is performed without de-coupling theinspection sensor from the corresponding upper portion. Providing theinspection robot may comprise providing the plurality of sleds with ahorizontal distribution such that an inspection distance between twohorizontally adjacent sleds of the plurality of sleds that is notgreater than a selected horizontal resolution.

In embodiments, an apparatus may comprise an upper portion of a sensorsled comprising a chamber; a lower portion of the sensor sledselectively coupled to the upper portion, the lower portion defining anaperture; wherein one of the upper portion and the lower portioncomprise a plurality of engagement keys, and wherein the other of theupper portion and the lower portion comprise a plurality of engagementslots; and wherein in a coupled position of the lower portion and theupper portion, the aperture the aperture is aligned with the chamber,the engagement keys are positioned in the engagement slots, and a bottomsurface of the lower portion faces away from the upper portion. Inembodiments, the apparatus may further comprise a sensor coupled to theupper portion, and wherein in a decoupled position of the lower portionand the upper portion, the sensor remains coupled to the upper portion.The sensor may be at least partially positioned in the chamber. Theupper portion may further comprise an installation tab, and wherein thesensor engages the installation tab to couple to the upper portion. Theapparatus may further comprise an installation sleeve at least partiallypositioned in the chamber, and wherein the sensor engages theinstallation sleeve to couple to the upper portion. The lower portionmay comprise a wholly integrated single material. The lower portion mayfurther comprise a recess structured to receive a film, the filmcovering at least a portion of the bottom surface. The film may compriseat least one of a sacrificial film and a low friction material.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic depiction of an inspection robot consistent withcertain embodiments of the present disclosure.

FIG. 2A is a schematic depiction of a wheel and splined hub designconsistent with certain embodiments of the present disclosure.

FIG. 2B is an exploded view of a wheel and splined hub design consistentwith certain embodiments of the present disclosure.

FIGS. 3A to 3C are schematic views of a sled consistent with certainembodiments of the present disclosure.

FIG. 4 is a schematic depiction of a payload consistent with certainembodiments of the present disclosure.

FIG. 5 is a schematic depiction of an inspection surface.

FIG. 6 is a schematic depiction of an inspection robot positioned on aninspection surface.

FIG. 7 is a schematic depiction of a location on an inspection surface.

FIG. 8 is a schematic block diagram of an apparatus for providing aninspection map.

FIG. 9 depicts an illustrative inspection map.

FIG. 10 depicts an illustrative inspection map and focus data.

FIGS. 11A to 11E are schematic depictions of wheels for an inspectionrobot.

FIG. 12 is a schematic depiction of a gearbox.

FIG. 13 is a schematic diagram of a payload arrangement.

FIG. 14 is another schematic diagram of a payload arrangement.

FIG. 15 is another schematic diagram of a payload arrangement.

FIG. 16 is a schematic perspective view of a sled.

FIG. 17 is a schematic side view of a sled.

FIG. 18 is a schematic cutaway view of a sled.

FIGS. 19A and 19B depict schematic side views of alternate embodimentsof a sled.

FIGS. 20A and 20B depict schematic front views of alternate embodimentsof a sled.

FIG. 21 is a schematic bottom view of a sled.

FIG. 22 is a schematic cutaway side view of a sled.

FIG. 23 is a schematic bottom view of a sled.

FIG. 24 is a schematic view of a sled having separable top and bottomportions.

FIG. 25 is a schematic cutaway side view of a sled.

FIG. 26 is a schematic exploded view of a sled with a sensor.

FIG. 27 is a schematic, partially exploded, partially cutaway view of asled with a sensor.

FIG. 28 is a schematic depiction of an acoustic cone.

FIG. 29 is a schematic view of couplant lines to a number of sleds.

FIG. 30 is a schematic flow diagram of a procedure to provide sensorsfor inspection of an inspection surface.

FIG. 31 is a schematic flow diagram of a procedure to re-couple a sensorto an inspection surface.

FIG. 32 is a schematic flow diagram of a procedure to provide for lowcouplant loss.

FIG. 33 is a schematic flow diagram of a procedure to perform aninspection at an arbitrary resolution.

FIG. 34 is a schematic block diagram of an apparatus for adjusting atrailing sensor configuration.

FIG. 35 is a schematic flow diagram of a procedure to adjust a trailingsensor configuration.

FIG. 36 is a schematic block diagram of an apparatus for providingposition informed inspection data.

FIG. 37 is a schematic flow diagram of a procedure to provide positioninformed inspection data.

FIG. 38 is a schematic flow diagram of another procedure to provideposition informed inspection data.

FIG. 39 is a schematic block diagram of an apparatus for providing anultra-sonic thickness value.

FIG. 40 is a schematic flow diagram of a procedure to provide anultra-sonic thickness value.

FIG. 41 is a schematic block diagram of an apparatus for providing afacility wear value.

FIG. 42 is a schematic flow diagram of a procedure to provide a facilitywear value.

FIG. 43 is a schematic block diagram of an apparatus for utilizing EMinduction data.

FIG. 44 is a schematic flow diagram of a procedure to utilize EMinduction data.

FIG. 45 is a schematic flow diagram of a procedure to determine acoating thickness and composition.

FIG. 46 is a schematic flow diagram of a procedure to re-process sensordata based on an induction process parameter.

FIG. 47 is a schematic block diagram of a procedure to utilize a shapedescription.

FIG. 48 is a schematic flow diagram of a procedure to adjust aninspection operation in response to profiler data.

DETAILED DESCRIPTION

The present disclosure relates to a system developed for traversing,climbing, or otherwise traveling over walls (curved or flat), or otherindustrial surfaces. Industrial surfaces, as described herein, includeany tank, pipe, housing, or other surface utilized in an industrialenvironment, including at least heating and cooling pipes, conveyancepipes or conduits, and tanks, reactors, mixers, or containers. Incertain embodiments, an industrial surface is ferromagnetic, for exampleincluding iron, steel, nickel, cobalt, and alloys thereof. In certainembodiments, an industrial surface is not ferromagnetic.

Certain descriptions herein include operations to inspect a surface, aninspection robot or inspection device, or other descriptions in thecontext of performing an inspection. Inspections, as utilized herein,should be understood broadly. Without limiting any other disclosures orembodiments herein, inspection operations herein include operating oneor more sensors in relation to an inspected surface, electromagneticradiation inspection of a surface (e.g., operating a camera) whether inthe visible spectrum or otherwise (e.g., infrared, UV, X-Ray, gamma ray,etc.), high-resolution inspection of the surface itself (e.g., a laserprofiler, caliper, etc.), performing a repair operation on a surface,performing a cleaning operation on a surface, and/or marking a surfacefor a later operation (e.g., for further inspection, for repair, and/orfor later analysis). Inspection operations include operations for apayload carrying a sensor or an array of sensors (e.g. on sensor sleds)for measuring characteristics of a surface being traversed such asthickness of the surface, curvature of the surface, ultrasound (orultra-sonic) measurements to test the integrity of the surface and/orthe thickness of the material forming the surface, heat transfer, heatprofile/mapping, profiles or mapping any other parameters, the presenceof rust or other corrosion, surface defects or pitting, the presence oforganic matter or mineral deposits on the surface, weld quality and thelike. Sensors may include magnetic induction sensors, acoustic sensors,laser sensors, LIDAR, a variety of image sensors, and the like. Theinspection sled may carry a sensor for measuring characteristics nearthe surface being traversed such as emission sensors to test for gasleaks, air quality monitoring, radioactivity, the presence of liquids,electro-magnetic interference, visual data of the surface beingtraversed such as uniformity, reflectance, status of coatings such asepoxy coatings, wall thickness values or patterns, wear patterns, andthe like. The term inspection sled may indicate one or more tools forrepairing, welding, cleaning, applying a treatment or coating thesurface being treated. Treatments and coatings may include rustproofing, sealing, painting, application of a coating, and the like.Cleaning and repairing may include removing debris, sealing leaks,patching cracks, and the like. The term inspection sled, sensor sled,and sled may be used interchangeably throughout the present disclosure.

In certain embodiments, for clarity of description, a sensor isdescribed in certain contexts throughout the present disclosure, but itis understood explicitly that one or more tools for repairing, cleaning,and/or applying a treatment or coating to the surface being treated arelikewise contemplated herein wherever a sensor is referenced. In certainembodiments, where a sensor provides a detected value (e.g., inspectiondata or the like), a sensor rather than a tool may be contemplated,and/or a tool providing a feedback value (e.g., application pressure,application amount, nozzle open time, orientation, etc.) may becontemplated as a sensor in such contexts.

Inspections are conducted with a robotic system 100 (e.g., an inspectionrobot, a robotic vehicle, etc.) which may utilize sensor sleds 1 and asled array system 2 which enables accurate, self-aligning, andself-stabilizing contact with a surface (not shown) while alsoovercoming physical obstacles and maneuvering at varying or constantspeeds. In certain embodiments, mobile contact of the system 100 withthe surface includes a magnetic wheel 3. In certain embodiments, a sledarray system 2 is referenced herein as a payload 2—wherein a payload 2is an arrangement of sleds 1 with sensor mounted thereon, and wherein,in certain embodiments, an entire payload 2 can be changed out as aunit. The utilization of payloads 2, in certain embodiments, allows fora pre-configured sensor array that provides for rapid re-configurationby swapping out the entire payload 2. In certain embodiments, sleds 1and/or specific sensors on sleds 1, are changeable within a payload 2 toreconfigure the sensor array.

An example sensor sled 1 includes, without limitation, one or moresensors mounted thereon such that the sensor(s) is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds. For example, the sled 1 may includea chamber or mounting structure, with a hole at the bottom of the sled 1such that the sensor can maintain line-of-sight and/or acoustic couplingwith the inspection surface. The sled 1 as described throughout thepresent disclosure is mounted on and/or operationally coupled to theinspection robot 100 such that the sensor maintains a specifiedalignment to the inspection surface 100—for example a perpendiculararrangement to the inspection surface, or any other specified angle. Incertain embodiments, a sensor mounted on a sled 1 may have aline-of-sight or other detecting arrangement to the inspection surfacethat is not through the sled 1—for example a sensor may be mounted at afront or rear of a sled 1, mounted on top of a sled 1 (e.g., having aview of the inspection surface that is forward, behind, to a side,and/or oblique to the sled 1). It will be seen that, regardless of thesensing orientation of the sensor to the inspection surface, maintenanceof the sled 1 orientation to the inspection surface will support moreconsistent detection of the inspection surface by the sensor, and/orsensed values (e.g., inspection data) that is more consistentlycomparable over the inspection surface and/or that has a meaningfulposition relationship compared to position information determined forthe sled 1 or inspection robot 100. In certain embodiments, a sensor maybe mounted on the inspection robot 100 and/or a payload 2—for example acamera mounted on the inspection robot 100.

The present disclosure allows for gathering of structural informationfrom a physical structure. Example physical structures includeindustrial structures such as boilers, pipelines, tanks, ferromagneticstructures, and other structures. An example system 100 is configuredfor climbing the outside of tube walls.

As described in greater detail below, in certain embodiments, thedisclosure provides a system that is capable of integrating input fromsensors and sensing technology that may be placed on a robotic vehicle.The robotic vehicle is capable of multi-directional movement on avariety of surfaces, including flat walls, curved surfaces, ceilings,and/or floors (e.g., a tank bottom, a storage tank floor, and/or arecovery boiler floor). The ability of the robotic vehicle to operate inthis way provides unique access especially to traditionally inaccessibleor dangerous places, thus permitting the robotic vehicle to gatherinformation about the structure it is climbing on.

The system 100 (e.g., an inspection robot, a robotic vehicle, and/orsupporting devices such as external computing devices, couplant or fluidreservoirs and delivery systems, etc.) in FIG. 1 includes the sled 1mounted on a payload 2 to provide for an array of sensors havingselectable contact (e.g., orientation, down force, sensor spacing fromthe surface, etc.) with an inspected surface. The payload 2 includesmounting posts mounted to a main body 102 of the system 100. The payload2 thereby provides a convenient mounting position for a number of sleds1, allowing for multiple sensors to be positioned for inspection in asingle traverse of the inspected surface. The number and distance of thesleds 1 on the payload 2 are readily adjustable—for example by slidingthe sled mounts on the payload 2 to adjust spacing. Referencing FIG. 3,an example sled 1 has an aperture 12, for example to provide forcouplant communication (e.g., an acoustically and/or opticallycontinuous path of couplant) between the sensor mounted on the sled 1and a surface to be inspected, to provide for line-of-sight availabilitybetween the sensor and the surface, or the like.

Referencing FIG. 4, an example system 100 includes the sled 1 held by anarm 20 that is connected to the payload 2 (e.g., a sensor array orsensor suite). An example system includes the sled 1 coupled to the arm20 at a pivot point 17, allowing the sensor sled to rotate and/or tilt.On top of the arm 20, an example payload 2 includes a biasing member 21(e.g., a torsion spring) with another pivot point 16, which provides fora selectable down-force of the arm 20 to the surface being inspected,and for an additional degree of freedom in sled 1 movement to ensure thesled 1 orients in a desired manner to the surface. In certainembodiments, down-force provides for at least a partial seal between thesensor sled 1 and surface to reduce or control couplant loss (e.g.,where couplant loss is an amount of couplant consumed that is beyondwhat is required for operations), control distance between the sensorand the surface, and/or to ensure orientation of the sensor relative tothe surface. Additionally or alternatively, the arm 20 can lift in thepresence of an obstacle, while traversing between surfaces, or the like,and return to the desired position after the maneuver is completed. Incertain embodiments, an additional pivot 18 couples the arm 20 to thepayload 2, allowing for an additional rolling motion. In certainembodiments, pivots 16, 17, 18 provide for three degrees of freedom onarm 20 motion, allowing the arm 20 to be responsive to almost anyobstacle or surface shape for inspection operations. In certainembodiments, various features of the system 100, including one or morepivots 16, 17, 18, co-operate to provide self-alignment of the sled 1(and thus, the sensor mounted on the sled) to the surface. In certainembodiments, the sled 1 self-aligns to a curved surface and/or to asurface having variability in the surface shape.

In certain embodiments, the system is also able to collect informationat multiple locations at once. This may be accomplished through the useof a sled array system. Modular in design, the sled array system allowsfor mounting sensor mounts, like the sleds, in fixed positions to ensurethorough coverage over varying contours. Furthermore, the sled arraysystem allows for adjustment in spacing between sensors, adjustments ofsled angle, and traveling over obstacles. In certain embodiments, thesled array system was designed to allow for multiplicity, allowingsensors to be added to or removed from the design, including changes inthe type, quantity, and/or physical sensing arrangement of sensors. Thesensor sleds that may be employed within the context of the presentinvention may house different sensors for diverse modalities useful forinspection of a structure. These sensor sleds are able to stabilize,align, travel over obstacles, and control, reduce, or optimize couplantdelivery which allows for improved sensor feedback, reduced couplantloss, reduced post-inspection clean-up, reduced down-time due to sensorre-runs or bad data, and/or faster return to service for inspectedequipment.

There may be advantages to maintaining a sled with associated sensors ortools in contact and/or in a fixed orientation relative to the surfacebeing traversed even when that surface is contoured, includes physicalfeatures, obstacles, and the like. In embodiments, there may be sledassemblies which are self-aligning to accommodate variabilities in thesurface being traversed (e.g., an inspection surface) while maintainingthe bottom surface of the sled (and/or a sensor or tool, e.g. where thesensor or tool protrudes through or is flush with a bottom surface ofthe sled) in contact with the inspection surface and the sensor or toolin a fixed orientation relative to the inspection surface. In anembodiment, as shown in FIG. 13 there may be a number of payloads 2,each payload 2 including a sled 1 positioned between a pair of sled arms20, with each side exterior of the sled 1 attached to one end of each ofthe sled arms 20 at a pivot point 17 so that the sled 1 is able torotate around an axis that would run between the pivot points 17 on eachside of the sled 1. As described elsewhere herein, the payload 2 mayinclude one or more inspection sleds 1 being pushed ahead of the payload2, pulled behind the payload 2, or both. The other end of each sled arm20 is attached to an inspection sled mount 14 with a pivot connection 16which allows the sled arms to rotate around an axis running through theinspection sled mount 14 between the two pivot connections 16.Accordingly, each pair of sled arms 20 can raise or lower independentlyfrom other sled arms 20, and with the corresponding sled 1. Theinspection sled mount 14 attaches to the payload 2, for example bymounting on shaft 19. The inspection sled mount 14 may connect to thepayload shaft 19 with a connection 18 which allows the sled 1 andcorresponding arms 20 to rotate from side to side in an arc around aperpendicular to the shaft 19. Together the up and down and side to sidearc, where present, allow two degrees of rotational freedom to the sledarms. Connection 18 is illustrated as a gimbal mount in the example ofFIG. 4, although any type of connection providing a rotational degree offreedom for movement is contemplated herein, as well as embodiments thatdo not include a rotational degree of freedom for movement. The gimbalmount 18 allows the sled 1 and associated arms 20 to rotate toaccommodate side to side variability in the surface being traversed orobstacles on one side of the sled 1. The pivot points 17 between thesled arms 20 and the sled 1 allow the sled 1 to rotate (e.g., tilt inthe direction of movement of the inspection robot 100) to conform to thesurface being traversed and accommodate to variations or obstacles inthe surface being traversed. Pivot point 17, together with therotational freedom of the arms, provides the sled three degrees ofrotational freedom relative to the inspection surface. The ability toconform to the surface being traversed facilitated the maintenance of aperpendicular interface between the sensor and the surface allowing forimproved interaction between the sled 1 and the inspection surface.Improved interaction may include ensuring that the sensor isoperationally couplable to the inspection surface.

Within the inspection sled mount 14 there may be a biasing member (e.g.,torsion spring 21) which provides a down force to the sled 1 andcorresponding arms 20. In the example, the down force is selectable bychanging the torsion spring, and/or by adjusting the configuration ofthe torsion spring (e.g., confining or rotating the torsion spring toincrease or decrease the down force). Analogous operations or structuresto adjust the down force for other biasing members (e.g., a cylindricalspring, actuator for active down force control, etc.) are contemplatedherein.

In certain embodiments, the inspection robot 100 includes a tether (notshown) to provide power, couplant or other fluids, and/or communicationlinks to the robot 100. It has been demonstrated that a tether tosupport at least 200 vertical feet of climbing can be created, capableof couplant delivery to multiple ultra-sonic sensors, sufficient powerfor the robot, and sufficient communication for real-time processing ata computing device remote from the robot. Certain aspects of thedisclosure herein, such as but not limited to utilizing couplantconservation features such as sled downforce configurations, theacoustic cone, and water as a couplant, support an extended length oftether. In certain embodiments, multiple ultra-sonic sensors can beprovided with sufficient couplant through a ⅛″ couplant delivery line,and/or through a ¼″ couplant delivery line to the inspection robot 100,with ⅛″ final delivery lines to individual sensors. While the inspectionrobot 100 is described as receiving power, couplant, and communicationsthrough a tether, any or all of these, or other aspects utilized by theinspection robot 100 (e.g., paint, marking fluid, cleaning fluid, repairsolutions, etc.) may be provided through a tether or provided in situ onthe inspection robot 100. For example, the inspection robot 100 mayutilize batteries, a fuel cell, and/or capacitors to provide power; acouplant reservoir and/or other fluid reservoir on the robot to providefluids utilized during inspection operations, and/or wirelesscommunication of any type for communications, and/or store data in amemory location on the robot for utilization after an inspectionoperation or a portion of an inspection operation.

In certain embodiments, maintaining sleds 1 (and sensors or toolsmounted thereupon) in contact and/or selectively oriented (e.g.,perpendicular) to a surface being traversed provides for: reduced noise,reduced lost-data periods, fewer false positives, and/or improvedquality of sensing; and/or improved efficacy of tools associated withthe sled (less time to complete a repair, cleaning, or markingoperation; lower utilization of associated fluids therewith; improvedconfidence of a successful repair, cleaning, or marking operation,etc.). In certain embodiments, maintaining sleds 1 in contacts and/orselectively oriented to the surface being traversed provides for reducedlosses of couplant during inspection operations.

In certain embodiments, the combination of the pivot points 16, 17, 18)and torsion spring 21 act together to position the sled 1 perpendicularto the surface being traversed. The biasing force of the spring 21 mayact to extend the sled arms 20 downward and away from the payload shaft19 and inspection sled mount 14, pushing the sled 1 toward theinspection surface. The torsion spring 21 may be passive, applying aconstant downward pressure, or the torsion spring 21 or other biasingmember may be active, allowing the downward pressure to be varied. In anillustrative and non-limiting example, an active torsion spring 21 mightbe responsive to a command to relax the spring tension, reducingdownward pressure and/or to actively pull the sled 1 up, when the sled 1encounters an obstacle, allowing the sled 1 to more easily move over theobstacle. The active torsion spring 21 may then be responsive to acommand to restore tension, increasing downward pressure, once theobstacle is cleared to maintain the close contact between the sled 1 andthe surface. The use of an active spring may enable changing the angleof a sensor or tool relative to the surface being traversed during atraverse. Design considerations with respect to the surfaces beinginspected may be used to design the active control system. If the spring21 is designed to fail closed, the result would be similar to a passivespring and the sled 1 would be pushed toward the surface beinginspected. If the spring 21 is designed to fail open, the result wouldbe increased obstacle clearance capabilities. In embodiments, spring 21may be a combination of passive and active biasing members.

The downward pressure applied by the torsion spring 21 may besupplemented by a spring within the sled 1 further pushing a sensor ortool toward the surface. The downward pressure may be supplemented byone or more magnets in/on the sled 1 pulling the sled 1 toward thesurface being traversed. The one or more magnets may be passive magnetsthat are constantly pulling the sled 1 toward the surface beingtraversed, facilitating a constant distance between the sled 1 and thesurface. The one or magnets may be active magnets where the magnet fieldstrength is controlled based on sensed orientation and/or distance ofthe sled 1 relative to the inspection surface. In an illustrative andnon-limiting example, as the sled 1 lifts up from the surface to clearan obstacle and it starts to roll, the strength of the magnet may beincreased to correct the orientation of the sled 1 and draw it backtoward the surface.

The connection between each sled 1 and the sled arms 20 may constitute asimple pin or other quick release connect/disconnect attachment. Thequick release connection at the pivot points 17 may facilitate attachingand detaching sleds 1 enabling a user to easily change the type ofinspection sled attached, swapping sensors, types of sensors, tools, andthe like.

In embodiments, as depicted in FIG. 16, there may be multiple attachmentor pivot point accommodations 9 available on the sled 1 for connectingthe sled arms 20. The location of the pivot point accommodations 9 onthe sled 1 may be selected to accommodate conflicting goals such as sled1 stability and clearance of surface obstacles. Positioning the pivotpoint accommodations 9 behind the center of sled in the longitudinaldirection of travel may facilitate clearing obstacles on the surfacebeing traversed. Positioning the pivot point accommodation 9 forward ofthe center may make it more difficult for the sled 1 to invert or flipto a position where it cannot return to a proper inspection operationposition. It may be desirable to alter the connection location of thesled arms 20 to the pivot point accommodations 9 (thereby defining thepivot point 17) depending on the direction of travel. The location ofthe pivot points 17 on the sled 1 may be selected to accommodateconflicting goals such as sensor positioning relative to the surface andavoiding excessive wear on the bottom of the sled. In certainembodiments, where multiple pivot point accommodations 9 are available,pivot point 17 selection can occur before an inspection operation,and/or be selectable during an inspection operation (e.g., arms 20having an actuator to engage a selected one of the pivot points 9, suchas extending pegs or other actuated elements, thereby selecting thepivot point 17).

In embodiments, the degree of rotation allowed by the pivot points 17may be adjustable. This may be done using mechanical means such as aphysical pin or lock. In embodiments, as shown in FIG. 17, theconnection between the sled 1 and the sled arms 20 may include a spring1702 that biases the pivot points 17 to tend to pivot in one directionor another. The spring 1702 may be passive, with the selection of thespring based on the desired strength of the bias, and the installationof the spring 1702 may be such as to preferentially push the front orthe back of the sled 1 down. In embodiments, the spring 1702 may beactive and the strength and preferential pivot may be varied based ondirection of travel, presence of obstacles, desired pivotingresponsiveness of the sled 1 to the presence of an obstacle or variationin the inspection surface, and the like. In certain embodiments,opposing springs or biasing members may be utilized to bias the sled 1back to a selected position (e.g., neutral/flat on the surface, tiltedforward, tilted rearward, etc.). Where the sled 1 is biased in a givendirection (e.g., forward or rearward), the sled 1 may neverthelessoperate in a neutral position during inspection operations, for exampledue to the down force from the arm 20 on the sled 1.

An example sled 1, for example as shown in FIG. 18, includes more thanone pivot point 17, for example utilizing springs 402 to couple to thesled arm 20. In the example of FIG. 16, the two pivot points 17 provideadditional clearance for the sled 1 to clear obstacles. In certainembodiments, both springs 402 may be active, for example allowing somerotation of each pivot simultaneously, and/or a lifting of the entiresled. In certain embodiments, springs 402 may be selectively locked—forexample before inspection operations and/or actively controlled duringinspection operations. Additionally or alternatively, selection of pivotposition, spring force and/or ease of pivoting at each pivot may beselectively controlled—for example before inspection operations and/oractively controlled during inspection operations (e.g., using acontroller 802). The utilization of springs 402 is a non-limitingexample of simultaneous multiple pivot points, and leaf springs,electromagnets, torsion springs, or other flexible pivot enablingstructures are contemplated herein. The spring tension or pivot controlmay be selected based on the uniformity of the surface to be traversed.The spring tension may be varied between the front and rear pivot pointsdepending on the direction of travel of the sled 1. In an illustrativeand non-limiting example, the rear spring (relative to the direction oftravel) might be locked and the front spring active when travelingforward to better enable obstacle accommodation. When direction oftravel is reversed, the active and locked springs 402 may be reversedsuch that what was the rear spring 402 may now be active and what wasthe front spring 402 may now be locked, again to accommodate obstaclesencountered in the new direction of travel.

In embodiments, the bottom surface of the sled 1 may be shaped, as shownin FIGS. 19A, 19B, with one or more ramps 1902 to facilitate the sled 1moving over obstacles encountered along the direction of travel. Theshape and slope of each ramp 1902 may be designed to accommodateconflicting goals such as sled 1 stability, speed of travel, and thesize of the obstacle the sled 1 is designed to accommodate. A steep rampangle might be better for accommodating large obstacles but may berequired to move more slowly to maintain stability and a goodinteraction with the surface. The slope of the ramp 1902 may be selectedbased on the surface to be traversed and expected obstacles. If the sled1 is interacting with the surface in only one direction, the sled 1 maybe designed with only one ramp 1902. If the sled 1 is interacting withthe surface going in two directions, the sled 1 may be designed with tworamps 1902, e.g., a forward ramp and a rearward ramp, such that the sled1 leads with a ramp 1902 in each direction of travel. Referencing FIG.19B, the front and rear ramps 1902 may have different angles and/ordifferent total height values. While the ramps 1902 depicted in FIGS.19A and 19B are linear ramps, a ramp 1902 may have any shape, includinga curved shape, a concave shape, a convex shape, and/or combinationsthereof. The selection of the ramp angle, total ramp height, and bottomsurface shape is readily determinable to one of skill in the art havingthe benefit of the disclosure herein and information ordinarilyavailable when contemplating a system. Certain considerations fordetermining the ramp angle, ramp total height, and bottom surface shapeinclude considerations of manufacturability, obstacle geometries likelyto be encountered, obstacle materials likely to be encountered,materials utilized in the sled 1 and/or ramp 1902, motive poweravailable to the inspection robot 100, the desired response toencountering obstacles of a given size and shape (e.g., whether it isacceptable to stop operations and re-configure the inspection operationsfor a certain obstacle, or whether maximum obstacle traversal capabilityis desired), and/or likely impact speed with obstacles for a sled.

In embodiments, as shown in FIGS. 20A and 20B, the bottom surface 2002of the sled 1 may be contoured or curved to accommodate a known textureor shape of the surface being traversed, for example such that the sled1 will tend to remain in a desired orientation (e.g., perpendicular)with the inspection surface as the sled 1 is moved. The bottom surface2002 of the sled 1 may be shaped to reduce rotation, horizontaltranslation and shifting, and/or yaw or rotation of the sled 1 from sideto side as it traverses the inspection surface. Referencing FIG. 20B,the bottom surface 2002 of the sled 1 may be convex for moving along arounded surface, on the inside of a pipe or tube, and/or along a groovein a surface. Referencing FIG. 20A, the bottom surface 2002 of the sled1 may be concave for the exterior of a rounded surface, such as ridingon an outer wall of a pipe or tube, along a rounded surface, and/oralong a ridge in a surface. The radius of curvature of the bottomsurface 2002 of the sled 1 may be selected to facilitate alignment giventhe curvature of the surface to be inspected. The bottom surface 2002 ofthe sled 1 may be shaped to facilitate maintaining a constant distancebetween sensors or tools in the sled 1 and the inspection surface beingtraversed. In embodiments, at least a portion the bottom of the sled 1may be flexible such that the bottom of the sled 1 may comply to theshape of the surface being traversed. This flexibility may facilitatetraversing surfaces that change curvature over the length of the surfacewithout the adjustments to the sled 1.

For a surface having a variable curvature, a chamfer or curve on thebottom surface 2002 of a sled 1 tends to guide the sled 1 to a portionof the variable curvature matching the curvature of the bottom surface2002. Accordingly, the curved bottom surface 2002 supports maintaining aselected orientation of the sled 1 to the inspection surface. In certainembodiments, the bottom surface 2002 of the sled 1 is not curved, andone or more pivots 16, 17, 18 combined with the down force from the arms20 combine to support maintaining a selected orientation of the sled 1to the inspection surface. In some embodiments, the bottom of the sled 1may be flexible such that the curvature may adapt to the curvature ofthe surface being traversed.

The material on the bottom of the sled 1 may be chosen to prevent wearon the sled 1, reduce friction between the sled 1 and the surface beingtraversed, or a combination of both. Materials for the bottom of thesled may include materials such as plastic, metal, or a combinationthereof. Materials for the bottom of the sled may include an epoxy coat,a replaceable layer of polytetrafluoroethylene (e.g., Teflon™), acetyl(e.g., Delrin® acetyl resin), ultrafine molecular weight polyethylene(PMW), and the like. In embodiments, as shown in FIG. 22, the materialon the bottom of the sled 1 may be removable layer such as a sacrificialfilm 2012 (or layer, and/or removable layer) that is applied to thebottom of the sled 1 and then lifted off and replaced at selectedintervals, before each inspection operation, and/or when the film 2012or bottom of the sled begin to show signs of wear or an increase infriction. An example sled 1 includes an attachment mechanism 2104, suchas a clip, to hold the sacrificial film 2012 in place. Referencing FIG.21, an example sled 1 includes a recess 2306 in the bottom surface ofthe sled to retain the sacrificial film 2012 and allow the sacrificialfilm 2012 to have a selected spatial orientation between the inspectioncontact side (e.g., the side of the sacrificial film 2012 exposed to theinspection surface) with the bottom surface 2002 of the sled 1 (e.g.,flush with the bottom, extending slightly past the bottom, etc.). Incertain embodiments, the removable layer may include a thickness thatprovides a selected spatial orientation between an inspection contactside in contact with the inspection surface and the bottom surface ofthe sled. In certain embodiments, the sacrificial film 2012 includes anadhesive, for example with an adhesive backing to the layer, and/or maybe applied as an adhesive (e.g., an epoxy layer or coating that isrefreshed or reapplied from time to time). An example sacrificial film2012 includes a hole therethrough, for example allowing for visualand/or couplant contact between a sensor 2202 attached to the sled 1 andthe inspection surface. The hole may be positioned over the sensor 2202,and/or may accommodate the sensor 2202 to extend through the sacrificialfilm 2012, and/or may be aligned with a hole 2016 (e.g., FIG. 21) oraperture 12 (e.g., FIG. 3B) in the sled bottom.

In embodiments, as shown in FIG. 22-24, an example sled 1 includes anupper portion 2402 and a replaceable lower portion 2404 having a bottomsurface. In some embodiments, the lower portion 2404 may be designed toallow the bottom surface and shape to be changed to accommodate thespecific surface to be traversed without having to disturb or change theupper portion 2402. Accordingly, where sensors or tools engage the upperportion 2402, the lower portion 2404 can be rapidly changed out toconfigure the sled 1 to the inspection surface, without disturbingsensor connections and/or coupling to the arms 20. The lower portion2404 may additionally or alternatively be configured to accommodate asacrificial layer 2012, including potentially with a recess 2306. Anexample sled 1 includes a lower portion 2404 designed to be easilyreplaced by lining up the upper portion 2402 and the lower portion 2404at a pivot point 2406, and then rotating the pieces to align the twoportions. In certain embodiments, the sensor, installation sleeve, conetip, or other portion protruding through aperture 12 forms the pivotpoint 2406. One or more slots 2408 and key 2410 interfaces or the likemay hold the two portions together.

The ability to quickly swap the lower portion 2404 may facilitatechanging the bottom surface of the sled 1 to improve or optimize thebottom surface of the sled 1 for the surface to be traversed. The lowerportion may be selected based on bottom surface shape, ramp angle, orramp total height value. The lower portion may be selected from amultiplicity of pre-configured replaceable lower portions in response toobserved parameters of the inspection surface after arrival to aninspection site. Additionally or alternatively, the lower portion 2404may include a simple composition, such as a wholly integrated part of asingle material, and/or may be manufactured on-site (e.g., in a 3-Dprinting operation) such as for a replacement part and/or in response toobserved parameters of the inspection surface after arrival to aninspection site. Improvement and/or optimization may include: providinga low friction material as the bottom surface to facilitate the sled 1gliding over the surface being traversed, having a hardened bottomsurface of the sled 1 if the surface to be traversed is abrasive,producing the lower portion 2404 as a wear material or low-costreplacement part, and the like. The replacement lower portion 2404 mayallow for quick replacement of the bottom surface when there is wear ordamage on the bottom surface of the sled 1. Additionally oralternatively, a user may alter a shape/curvature of the bottom of thesled, a slope or length of a ramp, the number of ramps, and the like.This may allow a user to swap out the lower portion 2404 of anindividual sled 1 to change a sensor to a similar sensor having adifferent sensitivity or range, to change the type of sensor, manipulatea distance between the sensor and the inspection surface, replace afailed sensor, and the like. This may allow a user to swap out the lowerportion 2404 of an individual sled 1 depending upon the surfacecurvature of the inspection surface, and/or to swap out the lowerportion 2404 of an individual sled 1 to change between various sensorsand/or tools.

In embodiments, as shown in FIGS. 25-27, a sled 1 may have a chamber2624 sized to accommodate a sensor 2202, and/or into which a sensor 2202may be inserted. The chamber 2624 may have chamfers 2628 on at least oneside of the chamber to facilitate ease of insertion and proper alignmentof the sensor 2202 in the chamber 2624. An example sled 1 includes aholding clamp 2630 that accommodates the sensor 2202 to passtherethrough, and is attached to the sled 1 by a mechanical device 2632such as a screw or the like. An example sled 1 includes stops 2634 atthe bottom of the chamber 2624, for example to ensure a fixed distancebetween the sensor 2202 and bottom surface of the sled and/or theinspection surface, and/or to ensure a specific orientation of thesensor 2202 to the bottom surface of the sled and/or the inspectionsurface.

Referencing FIG. 27, an example sled 1 includes a sensor installationsleeve 2704, which may be positioned, at least partially, within thechamber. The example sensor installation sleeve 2704 may be formed froma compliant material such as neoprene, rubber, an elastomeric material,and the like, and in certain embodiments may be an insert into a chamber2624, a wrapper material on the sensor 2202, and/or formed by thesubstrate of the sled 1 itself (e.g., by selecting the size and shape ofthe chamber 2624 and the material of the sled 1 at least in the area ofthe chamber 2624). An example sleeve 2704 includes an opening 2 sized toreceive a sensor 2202 and/or a tool (e.g., marking, cleaning, repair,and/or spray tool). In the example of FIG. 27, the sensor installationsleeve 2704 flexes to accommodate the sensor 2202 as the sensor 2202 isinserted. Additionally or alternatively, a sleeve 2704 may include amaterial wrapping the sensor 2202 and slightly oversized for the chamber2624, where the sleeve compresses through the hole into the chamber2624, and expands slightly when released, thereby securing the sensor2202 into the sled 1. In the example of FIG. 27, an installation tab2716 is formed by relief slots 2714. The tab 2716 flexes to engage thesensor 2202, easing the change of the sensor 2202 while securing thesensor 2202 in the correct position once inserted into the sled 1.

It can be seen that a variety of sensor and tool types and sizes may beswapped in and out of a single sled 1 using the same sensor installationsleeve 2704. The opening of the chamber 2624 may include the chamfers2628 to facilitate insertion, release, and positioning of the sensor2202, and/or the tab 2716 to provide additional compliance to facilitateinsertion, release, and positioning of the sensor 2202 and/or toaccommodate varying sizes of sensors 2202. Throughout the presentdisclosure, a sensor 2202 includes any hardware of interest forinserting or coupling to a sled 1, including at least: a sensor, asensor housing or engagement structure, a tool (e.g., a sprayer, marker,fluid jet, etc.), and/or a tool housing or engagement structure.

Referencing FIG. 28, an acoustic cone 2804 is depicted. The acousticcone 2804 includes a sensor interface 2808, for example to couple anacoustic sensor with the cone 2804. The example acoustic cone 2804includes a couplant interface 2814, with a fluid chamber 2818 couplingthe couplant interface 2814 to the cone fluid chamber 2810. In certainembodiments, the cone tip 2820 of the acoustic cone 2804 is kept incontact with the inspection surface, and/or kept at a predetermineddistance from the inspection surface while the acoustic sensor ismounted at the opposite end of the acoustic cone 2804 (e.g., at sensorinterface 2808). The cone tip 2820 may define a couplant exit openingbetween the couplant chamber and the inspection surface. The couplantexit opening may be flush with the bottom surface or extend through thebottom of the sled. Accordingly, a delay line (e.g., acoustic orvibration coupling of a fixed effective length) between the sensor andthe inspection surface is kept at a predetermined distance throughoutinspection operations. Additionally, the acoustic cone 2804 couples tothe sled 1 in a predetermined arrangement, allowing for replacement ofthe sensor, and/or swapping of a sled 1 without having to recalibrateacoustic and/or ultra-sonic measurements. The volume between the sensorand the inspection surface is maintained with couplant, providing aconsistent delay line between the sensor and the inspection surface.Example and non-limiting couplant fluids include alcohol, a dyepenetrant, an oil-based liquid, an ultra-sonic gel, or the like. Anexample couplant fluid includes particle sizes not greater than 1/16 ofan inch. In certain embodiments, the couplant is filtered beforedelivery to the sled 1. In certain embodiments, the couplant includeswater, which is low cost, low viscosity, easy to pump and compatiblewith a variety of pump types, and may provide lower resistance to themovement of the inspection sled over the surface than gels. In certainembodiments, water may be an undesirable couplant, and any type ofcouplant fluid may be provided.

An example acoustic cone 2804 provides a number of features to preventor remove air bubbles in the cone fluid chamber 2810. An exampleacoustic cone 2804 includes entry of the fluid chamber 2818 into avertically upper portion of the cone fluid chamber 2810 (e.g., as theinspection robot 100 is positioned on the inspection surface, and/or inan intended orientation of the inspection robot 100 on the inspectionsurface, which may toward the front of the robot where the robot isascending vertically), which tends to drive air bubbles out of the conefluid chamber 2810. In certain embodiments, the utilization of theacoustic cone 2804, and the ability to minimize sensor coupling andde-coupling events (e.g., a sled can be swapped out without coupling ordecoupling the sensor from the cone) contributes to a reduction in leaksand air bubble formation. In certain embodiments, a controller 802periodically and/or in response to detection of a potential air bubble(e.g., due to an anomalous sensor reading) commands a de-bubblingoperation, for example increasing a flow rate of couplant through thecone 2804. In certain embodiments, the arrangements described throughoutthe present disclosure provide for sufficient couplant delivery to be inthe range of 0.06 to 0.08 gallons per minute using a ⅛″ fluid deliveryline to the cone 2804. In certain embodiments, nominal couplant flow andpressure is sufficient to prevent the formation of air bubbles in theacoustic cone 2804.

As shown in FIG. 29, individual tubing 2902 may be connected to eachcouplant interface 2814. In some embodiments, the individual tubing 2902may be connected directly to a sled 1A, 1B rather than the individualtubing 2902, for example with sled 1A, 1B plumbing permanently coupledto the couplant interface 2814. Two or more individual tubing 2902sections may then be joined together in a tubing junction 2908 with asingle tube 2904 leaving the junction. In this way, a number ofindividual tubes 2902 may be reduced to a single tube 2904 that may beeasily connected/disconnected from the source of the couplant. Incertain embodiments, an entire payload 2 may include a single couplantinterface, for example to the inspection robot 100. The inspection robot100 may include a couplant reservoir and/or a delivery pump thereupon,and/or the inspection robot 100 may be connected to an external couplantsource. In certain embodiments, an entire payload 2 can be changed outwith a single couplant interface change, and without any of the conecouplant interfaces and/or sensor couplant interface being disconnected.In certain embodiments, the integration of the sensor 2202, acousticcone 2804, and cone tip 2820 is designed to maintain a constant distancebetween the surface being measured and the acoustic sensor 2202. Theconstant distance facilitates in the interpretation of the data recordedby the acoustic sensor 2202. In certain embodiments, the distancebetween the surface being measured and the acoustic sensor 2202 may bedescribed as the “delay line.”

Certain embodiments include an apparatus for providing acoustic couplingbetween a carriage (or sled) mounted sensor and an inspection surface.Example and non-limiting structures to provide acoustic coupling betweena carriage mounted sensor and an inspection surface include an acoustic(e.g., an ultra-sonic) sensor mounted on a sled 1, the sled 1 mounted ona payload 2, and the payload 2 coupled to an inspection robot. Anexample apparatus further includes providing the sled 1 with a number ofdegrees of freedom of motion, such that the sled 1 can maintain aselected orientation with the inspection surface—including aperpendicular orientation and/or a selected angle of orientation.Additionally or alternatively, the sled 1 is configured to track thesurface, for example utilizing a shaped bottom of the sled 1 to match ashape of the inspection surface or a portion of the inspection surface,and/or the sled 1 having an orientation such that, when the bottomsurface of the sled 1 is positioned against the inspection surface, thesensor maintains a selected angle with respect to the inspectionsurface.

Certain additional embodiments of an apparatus for providing acousticcoupling between a carriage mounted sensor and an inspection surfaceinclude utilization of a fixed-distance structure that ensures aconsistent distance between the sensor and the inspection surface. Forexample, the sensor may be mounted on a cone, wherein an end of the conetouches the inspection surface and/or is maintained in a fixed positionrelative to the inspection surface, and the sensor mounted on the conethereby is provided at a fixed distance from the inspection surface. Incertain embodiments, the sensor may be mounted on the cone, and the conemounted on the sled 1, such that a change-out of the sled 1 can beperformed to change out the sensor, without engaging or disengaging thesensor from the cone. In certain embodiments, the cone may be configuredsuch that couplant provided to the cone results in a filled couplantchamber between a transducer of the sensor and the inspection surface.In certain additional embodiments, a couplant entry position for thecone is provided at a vertically upper position of the cone, between thecone tip portion and the sensor mounting end, in an orientation of theinspection robot as it is positioned on the surface, such that couplantflow through the cone tends to prevent bubble formation in the acousticpath between the sensor and the inspection surface. In certain furtherembodiments, the couplant flow to the cone is adjustable, and iscapable, for example, to be increased in response to a determinationthat a bubble may have formed within the cone and/or within the acousticpath between the sensor and the inspection surface. In certainembodiments, the sled 1 is capable of being lifted, for example with anactuator that lifts an arm 20, and/or that lifts a payload 2, such thata free fluid path for couplant and attendant bubbles to exit the coneand/or the acoustic path is provided. In certain embodiments, operationsto eliminate bubbles in the cone and/or acoustic path are performedperiodically, episodically (e.g., after a given inspection distance iscompleted, at the beginning of an inspection run, after an inspectionrobot pauses for any reason, etc.), and/or in response to an activedetermination that a bubble may be present in the cone and/or theacoustic path.

An example apparatus provides for low or reduced fluid loss of couplantduring inspection operations. Example and non-limiting structures toprovide for low or reduced fluid loss include providing for a limitedflow path of couplant out of the inspection robot system—for exampleutilizing a cone having a smaller exit couplant cross-sectional areathan a cross-sectional area of a couplant chamber within the cone. Incertain embodiments, an apparatus for low or reduced fluid loss ofcouplant includes structures to provide for a selected down force on asled 1 which the sensor is mounted on, on an arm 20 carrying a sled 1which the sensor is mounted on, and/or on a payload 2 which the sled 1is mounted on. Additionally or alternatively, an apparatus providing forlow or reduced fluid loss of couplant includes a selected down force ona cone providing for couplant connectivity between the sensor and theinspection surface—for example a leaf spring or other biasing memberwithin the sled 1 providing for a selected down force directly to thecone. In certain embodiments, low or reduced fluid loss includesproviding for an overall fluid flow of between 0.12 to 0.16 gallons perminute to the inspection robot to support at least 10 ultra-sonicsensors. In certain embodiments, low or reduced fluid loss includesproviding for an overall fluid flow of less than 50 feet per minute,less than 100 feet per minute, and less than 200 feet per minute fluidvelocity in a tubing line feeding couplant to the inspection robot. Incertain embodiments, low or reduced fluid loss includes providingsufficient couplant through a ¼″ tubing line to feed couplant to atleast 6, at least 8, at least 10, at least 12, or at least 16ultra-sonic sensors to a vertical height of at least 25 feet, at least50 feet, at least 100 feet, at least 150 feet, or at least 200 feet. Anexample apparatus includes a ¼″ feed line to the inspection robot and/orto the payload 2, and a ⅛″ feed line to individual sleds 1 and/orsensors (or acoustic cones associated with the sensors). In certainembodiments, larger and/or smaller diameter feed and individual fluidlines are provided.

Referencing FIG. 30, an example procedure 3000 to provide acousticcoupling between a sensor and an inspection surface is depictedschematically. The example procedure 3000 includes an operation 3002 toprovide a fixed acoustic path between the sensor and the inspectionsurface. The example procedure 3000 further includes an operation 3004to fill the acoustic path with a couplant. The example procedure 3000further includes an operation 3006 to provide for a selected orientationbetween the sensor and the inspection surface. In certain embodiments,certain operations of the procedure 3000 are performed iterativelythroughout inspection operations—for example operations 3006 may includemaintaining the orientation throughout inspection operations—such asproviding the sensor on a sled having a bottom surface and/ormaneuverability to passively or actively self-align to the inspectionsurface, and/or to return to alignment after a disturbance such astraversal of an obstacle. In another example, operations 3004 includeproviding a couplant flow to keep the acoustic path between the sensorand the inspection surface filled with couplant, and/or adjusting thecouplant flow during inspection operations. Certain operations ofprocedure 3000 may be performed by a controller 802 during inspectionoperations.

Referencing FIG. 31, an example procedure 3100 to ensure acousticengagement between a sensor and an inspection surface is depictedschematically. The example procedure 3100 includes an operation 3102 toprovide an acoustic coupling chamber between the sensor and theinspection surface. Example and non-limiting operations 3102 includeproviding the acoustic coupling chamber with an arrangement that tendsto reduce bubble formation within the acoustic path between the sensorand the inspection surface. The example procedure 3100 further includesan operation 3104 to determine that the sensor should be re-coupled tothe inspection surface. Example and non-limiting operations 3104 includedetermining that a time has elapsed since a last re-coupling operation,determining that an event has occurred and performing a re-couplingoperation in response to the event, and/or actively determining that theacoustic path has been interrupted. Example and non-limiting eventsinclude a pausing of the inspection robot, a beginning of inspectionoperations and/or completion of a selected portion of inspectionoperations, and/or an interruption of couplant flow to the inspectionrobot. Example and non-limiting operation to actively determine that theacoustic path has been interrupted include an observation of a bubble(e.g., in an acoustic cone), an indication that couplant may have exitedthe acoustic path (e.g., the sled 1 has lifted either for an obstacle orfor another operation, observation of an empty cone, etc.), and/or anindication that a sensor reading is off-nominal (e.g., signal seems tohave been lost, anomalous reading has occurred, etc.). The exampleprocedure 3100 further includes an operation 3106 to re-couple thesensor to the inspection surface. Example and non-limiting operations3106 include resuming and/or increasing a couplant flow rate, and/orbriefly raising a sled, sled arm, and/or payload from the inspectionsurface. The procedure 3100 and/or portions thereof may be repeatediteratively during inspection operations. Certain operations ofprocedure 3100 may be performed by a controller 802 during inspectionoperations.

Referencing FIG. 32, an example procedure 3200 to provide low fluid loss(and/or fluid consumption) between an acoustic sensor and an inspectionsurface is depicted schematically. An example procedure 3200 includes anoperation 3202 to provide for a low exit cross-sectional area forcouplant from an acoustic path between the sensor and the inspectionsurface—including at least providing an exit from a couplant chamberformed by a cone as the exit cross-sectional area, and/or providing anexit cross-sectional area that is in a selected proximity to, and/or incontact with, the inspection surface. The example procedure 3200 furtherincludes an operation 3204 to provide a selected down force to a sledhaving the sensor mounted thereon, and/or to a couplant chamber. Incertain embodiments, the example procedure 3200 includes an operation3206 to determine if fluid loss for the couplant is excessive (e.g., asmeasured by replacement couplant flow provided to an inspection robot,and/or by observed couplant loss), and an operation 3208 to increase adown force and/or reduce a couplant exit cross-sectional area from acouplant chamber. In certain embodiments, an inspection robot includes aconfigurable down force, such as: an active magnet strength control; abiasing member force adjustment (e.g., increasing confinement of aspring to increase down force); sliding of a weight in a manner toadjust down force on the sled and/or cone; combinations of these; or thelike. In certain embodiments, an exit cross-sectional are for couplantis adjustable—for example an iris actuator (not shown), gate valve, orcross-sectional area adjustment is provided. In certain embodiments,cross-sectional area is related to the offset distance of the couplantchamber exit (e.g., cone tip) from the inspection surface, whereby areduction of the selected offset distance of the couplant chamber exitto the inspection surface reduces the effective exit flow area of thecouplant chamber. Example operations to adjust the selected offsetdistance include lowering the couplant chamber within the sled and/orincreasing a down force on the sled and/or couplant chamber. Certainoperations of procedure 3200 may be performed by a controller 802 duringinspection operations.

Referencing FIGS. 2A and 2B, an example system includes a wheel 200design that enables modularity, adhesion to the structure's surface, andobstacle traversing. A splined hub, wheel size, and the use of magnetsallow the system to be effective on many different surfaces. In someembodiments, the wheel 200 includes a splined hub 8. The wheel 200permits a robotic vehicle 100 to climb on walls, ceilings, and otherferromagnetic surfaces. As shown in the embodiment depicted in FIGS. 2Aand 2B, this may be accomplished by embedding magnets 6 in aferromagnetic enclosure 3 and/or an electrically conductive enclosure toprotect the magnet 6, improve alignment, and allow for ease of assembly.For example, the magnet 6 may be a permanent magnet and/or acontrollable electromagnet, and may further include a rare earth magnet.The ferromagnetic enclosure 3 protects the magnet 6 from directlyimpacting the inspected surface, reduces impacts and damage to themagnet 6, and reduces wear on the surface and the magnet 6. Theferromagnetic and/or electrical conductivity of the enclosure 3 reducesmagnetic field lines in not-useful directions (e.g., into the housing102, electrical lines or features that may be present near the inspectedsurface, etc.) and guides the magnetic field lines to the inspectedsurface. In certain embodiments, the enclosure 3 may not beferromagnetic or conductive, and/or the enclosure 3 may be at leastpartially covered by a further material (e.g., molded plastic, acoating, paint, etc.), for example to protect the inspected surface fromdamage, to protect the enclosure 3 from wear, for aesthetic reasons, orfor any other reason. In certain embodiments, the magnet 6 is notpresent, and the system 100 stays in contact with the surface in anothermanner (e.g., surface tension adhesion, gravity such as on a horizontalor slightly inclined inspection surface, movement along a track fixed tothe surface, or the like). Any arrangements of an inspection surface,including vertical surfaces, overhang or upside-down surfaces, curvedsurfaces, and combinations of these, are contemplated herein.

The wheel 200 includes a channel 7 formed between enclosures 3, forexample at the center of the wheel 200. In certain embodiments, thechannel 7 provides for self-alignment on surfaces such as tubes orpipes. In certain embodiments, the enclosures 300 include one or morechamfered edges or surfaces (e.g., the outer surface in the example ofFIG. 3), for example to improve contact with a rough or curved surface,and/or to provide for a selected surface contact area to avoid damage tothe surface and/or the wheel 200. The flat face along the rim alsoallows for adhesion and predictable movement on flat surfaces.

The wheel 200 may be connected to the shaft using a splined hub 8. Thisdesign makes the wheel modular and also prevents it from binding due tocorrosion. The splined hub 8 transfers the driving force from the shaftto the wheel. An example wheel 200 includes a magnetic aspect (e.g.,magnet 6) capable to hold the robot on the wall, and accept a drivingforce to propel the robot, the magnet 6 positioned between conductiveand/or ferromagnetic plates or enclosures, a channel 7 formed by theenclosures or plates, one or more chamfered and/or shaped edges, and/ora splined hub attachment to a shaft upon which the wheel is mounted.

The robotic vehicle may utilize a magnet-based wheel design that enablesthe vehicle to attach itself to and operate on ferromagnetic surfaces,including vertical and inverted surfaces (e.g., walls and ceilings). Asshown in FIGS. 2A and 2B, the wheel design may comprise a cylindricalmagnet 6 mounted between two wheel enclosures 3 with a splined hub 8design for motor torque transfer, where the outer diameter of the twoenclosures 3 is greater than the outer diameter of the magnet 6. Onceassembled, this configuration creates a channel 7 between the two wheelenclosures 3 that prevents the magnet 6 from making physical contactwith the surface as the wheel rolls on the outer diameter surface of thewheel enclosures 3. In certain embodiments, the material of the magnet 6may include a rare earth material (e.g., neodymium, yttrium-cobalt,samarium-cobalt, etc.), which may be expensive to produce, handle,and/or may be highly subject to damage or corrosion. Additionally, anypermanent magnet material may have a shorter service life if exposed todirect shocks or impacts.

The channel 7 may also be utilized to assist in guiding the roboticvehicle along a feature of an inspection surface 500 (e.g., referenceFIG. 5), such as where the channel 7 is aligned along the top of arounded surface (e.g., pipe, or other raised feature) that the wheeluses to guide the direction of travel. The wheel enclosures 3 may alsohave guiding features 2052 (reference FIGS. 11A to 11E), such asgrooves, concave or convex curvature, chamfers on the inner and/or outeredges, and the like. Referencing FIG. 11A, an example guiding feature2052 includes a chamfer on an outer edge of one or both enclosures 3,for example providing self-alignment of the wheels along a surfacefeature, such as between raised features, on top of raised features,between two pipes 502 (which may be adjacent pipes or spaced pipes),and/or a curvature of a tube, pipe, or tank (e.g., when the inspectionrobot 100 traverses the interior of a pipe 502). For instance, having achamfer on the outer edge of the outside enclosure may enable the wheelto more easily seat next to and track along a pipe 502 that is locatedoutside the wheel. In another instance, having chamfers on both edgesmay enable the wheel to track with greater stability between two pipes502. Referencing FIG. 11B, guiding features 2052 are depicted aschamfers on both sides of the wheel enclosures 3—for example allowingthe inspection robot 100 to traverse between pipes 502; on top of asingle pipe 502 or on top of a span of pipes 502; along the exterior ofa pipe, tube, or tank; and/or along the interior of a pipe, tube, ortank. Referencing FIG. 11C, guiding features 2052 are depicted aschamfers on the interior channel 7 side of the enclosures 3, for exampleallowing the wheel to self-align on top of a single pipe or otherfeature. Referencing FIG. 11D, guiding features 2052 are depicted as aconcave curved surface, for example sized to match a pipe or otherfeature to be traversed by the wheel. Referencing FIG. 11E, guidingfeatures 2052 are depicted as a concave curved surface formed on aninterior of the channel 7, with chamfers 2052 on the exterior of theenclosure 3—for example allowing the wheel to self-align on a singlepipe or feature on the interior of the enclosure, and/or to alignbetween pipes on the exterior of the enclosure.

One skilled in the art will appreciate that a great variety of differentguiding features 2052 may be used to accommodate the different surfacecharacteristics to which the robotic vehicle may be applied. In certainembodiments, combinations of features (e.g., reference FIG. 11E) providefor the inspection robot 100 to traverse multiple surfaces for a singleinspection operation, reducing change-time for the wheels and the like.In certain embodiments, chamfer angles, radius of curvature, verticaldepth of chamfers or curves, and horizontal widths of chamfers or curvesare selectable to accommodate the sizing of the objects to be traversedduring inspection operations. It can be seen that the down forceprovided by the magnet 6 combined with the shaping of the enclosure 3guiding features 2052 combine to provide for self-alignment of theinspection robot 100 on the surface 500, and additionally provide forprotection of the magnet 6 from exposure to shock, impacts, and/ormaterials that may be present on the inspection surface. In certainembodiments, the magnet 6 may be shaped—for example with curvature(reference FIG. 11D), to better conform to the inspection surface 500and/or prevent impact or contact of the magnet 6 with the surface.

Additionally or alternatively, guiding features may be selectable forthe inspection surface—for example multiple enclosures 3 (and/ormultiple wheel assemblies including the magnet 6 and enclosure 3) may bepresent for an inspection operation, and a suitable one of the multipleenclosures 3 provided according to the curvature of surfaces present,the spacing of pipes, the presence of obstacles, or the like. In certainembodiments, an enclosure 3 may have an outer layer (e.g., a removablelayer—not shown)—for example a snap on, slide over, coupled with setscrews, or other coupling mechanism for the outer layer, such that justan outer portion of the enclosure is changeable to provide the guidingfeatures. In certain embodiments, the outer layer may be a non-ferrousmaterial (e.g., making installation and changes of the outer layer moreconvenient in the presence to the magnet 6, which may complicate quickchanges of a fully ferromagnetic enclosure 3), such as a plastic,elastomeric material, aluminum, or the like. In certain embodiments, theouter layer may be a 3-D printable material (e.g., plastics, ceramics,or any other 3-D printable material) where the outer layer can beconstructed at an inspection location after the environment of theinspection surface 500 is determined. An example includes the controller802 (e.g., reference FIG. 8 and the related description) structured toaccept inspection parameters (e.g., pipe spacing, pipe sizes, tankdimensions, etc.), and to provide a command to a 3-D printer responsiveto the command to provide an outer layer configured for the inspectionsurface 500. In certain embodiments, the controller 802 further acceptsan input for the wheel definition (e.g., where selectable wheel sizes,clearance requirements for the inspection robot 100, or other parametersnot necessarily defined by the inspection surface 500), and furtherprovides the command to the 3-D printer, to provide an outer layerconfigured for the inspection surface 500 and the wheel definition.

An example splined hub 8 design of the wheel assembly may enable modularre-configuration of the wheel, enabling each component to be easilyswitched out to accommodate different operating environments (e.g.,ferromagnetic surfaces with different permeability, different physicalcharacteristics of the surface, and the like). For instance, enclosureswith different guiding features may be exchanged to accommodatedifferent surface features, such as where one wheel configuration workswell for a first surface characteristic (e.g., a wall with tightlyspaced small pipes) and a second wheel configuration works well for asecond surface characteristic (e.g., a wall with large pipes). Themagnet 6 may also be exchanged to adjust the magnetic strength availablebetween the wheel assembly and the surface, such as to accommodatedifferent dimensional characteristics of the surface (e.g., featuresthat prevent close proximity between the magnet 6 and a surfaceferromagnetic material), different permeability of the surface material,and the like. Further, one or both enclosures 3 may be made offerromagnetic material, such as to direct the flux lines of the magnettoward a surface upon which the robotic vehicle is riding, to direct theflux lines of the magnet away from other components of the roboticvehicle, and the like, enabling the modular wheel configuration to befurther configurable for different ferromagnetic environments andapplications.

The present disclosure provides for robotic vehicles that include asensor sled components, permitting evaluation of particular attributesof the structure. As shown in the embodiments depicted in FIGS. 3A to3C, the sled 1 may hold the sensor that can perform inspection of thestructure. The sensor may be perpendicular to the surface beinginspected and, in some embodiments, may have a set distance from thesurface to protect it from being damaged. In other embodiments, thedistance from the surface to the sensor may be adjusted to accommodatethe technical requirements of the sensor being utilized. A couplantretaining column may be added at the sensor outlet to retain couplantdepending on the type of sensor being used. In certain embodiments, anopening 12 may be provided at a bottom of the sled 1 to allow aninstalled sensor to operatively communicate with an inspection surface.

The sleds of the present disclosure may slide on a flat or curvedsurface and may perform various types of material testing using thesensors incorporated into the sled. The bottom surface 13 of the sledmay be fabricated from numerous types of materials which may be chosenby the user to fit the shape of the surface. Note that depending on thesurface condition, a removeable, replaceable, and/or sacrificial layerof thin material may be positioned on the bottom surface of the sled toreduce friction, create a better seal, and protect the bottom of thesled from physical damage incurred by the surface. In certainembodiments, the sled may include ramp surfaces 11 at the front and backof the sled. The ramp and available pivot point accommodation 9(described below—for example an option for pivot point 17) give the sledthe ability to travel over obstacles. This feature allows the sled towork in industrial environments with surfaces that are not clean andsmooth. In certain embodiments, one or more apertures 10 may beprovided, for example to allow a sacrificial layer to be fixed to thebottom of the sled 1.

In summary, an example robotic vehicle 100 includes sensor sleds havingthe following properties capable of providing a number of sensors forinspecting a selected object or surface, including a soft or hard bottomsurface, including a bottom surface that matches an inspection surface(e.g., shape, contact material hardness, etc.), having a curved surfaceand/or ramp for obstacle clearance (including a front ramp and/or a backramp), includes a column and/or couplant insert (e.g., a cone positionedwithin the sled, where the sensor couples to the cone) that retainscouplant, improves acoustic coupling between the sensor and the surface,and/or assists in providing a consistent distance between the surfaceand the sensor; a plurality of pivot points between the main body 102and the sled 1 to provide for surface orientation, improved obstacletraversal, and the like, a sled 1 having a mounting position configuredto receive multiple types of sensors, and/or magnets in the sled toprovide for control of downforce and/or stabilized positioning betweenthe sensor and the surface. In certain implementations of the presentinvention, it is advantageous to not only be able to adjust spacingbetween sensors but also to adjust their angular position relative tothe surface being inspected. The present invention may achieve this goalby implementing systems having several translational and rotationaldegrees of freedom.

Referencing FIG. 4, an example payload 2 includes selectable spacingbetween sleds 1, for example to provide selectable sensor spacing. Incertain embodiments, spacing between the sensors may be adjusted using alockable translational degree of freedom such as a set screw 14 allowingfor the rapid adjustment of spacing. Additionally or alternatively, anycoupling mechanism between the arm 20 and the payload 2 is contemplatedherein. In certain embodiments, a worm gear or other actuator allows forthe adjustment of sensor spacing by a controller and/or in real timeduring operations of the system 100. In certain embodiments, the payload2 includes a shaft 19 whereupon sleds 1 are mounted (e.g., via the arms20). In these embodiments, the sensor mounts 14 are mounted on a shaft19. The example of FIG. 4 includes a shaft cap 15 providing structuralsupport to a number of shafts of the payload 2. In the example of FIG.4, two shafts are utilized to mount the payload 2 onto the housing 102,and one shaft 19 is utilized to mount the arms 20 onto the payload 2.The arrangement utilizing a payload 2 is a non-limiting example, thatallows multiple sensors and sleds 1 to be configured in a particulararrangement, and rapidly changed out as a group (e.g., swapping out afirst payload and set of sensors for a second payload and set ofsensors, thereby changing an entire sensor arrangement in a singleoperation). However, in certain embodiments one or more of the payload2, arms 20, and/or sleds 1 may be fixedly coupled to the respectivemounting features, and numerous benefits of the present disclosure arenevertheless achieved in such embodiments.

During operation, an example system 100 encounters obstacles on thesurface of the structure being evaluated, and the pivots 16, 17, 18provide for movement of the arm 20 to traverse the obstacle. In certainembodiments, the system 100 is a modular design allowing various degreesof freedom of movement of sleds 1, either in real-time (e.g., during aninspection operation) and/or at configuration time (e.g., an operator orcontroller adjusts sensor or sled positions, down force, ramp shapes ofsleds, pivot angles of pivots 16, 17, 18 in the system 100, etc.) beforean inspection operation or a portion of an inspection operation, andincluding at least the following degrees of freedom: translation (e.g.,payload 2 position relative to the housing 102); translation of the sledarm 20 relative to the payload 2, rotation of the sled arm 20, rotationof the sled arm 20 mount on the payload 2, and/or rotation of the sled 1relative to the sled arm 20.

In certain embodiments, a system 100 allows for any one or more of thefollowing adjustments: spacing between sensors (perpendicular to thedirection of inspection motion, and/or axially along the direction ofthe inspection motion); adjustments of an angle of the sensor to anouter diameter of a tube or pipe; momentary or longer term displacementto traverse obstacles; provision of an arbitrary number and positioningof sensors; etc.

An example inspection robot 100 may utilize downforce capabilities forsensor sleds 1, such as to control proximity and lateral stabilizationof sensors. For instance, an embedded magnet (not shown) positionedwithin the sled 1 may provide passive downforce that increasesstabilization for sensor alignment. In another example, the embeddedmagnet may be an electromagnet providing active capability (e.g.,responsive to commands from a controller 802—reference FIG. 8) thatprovide adjustable or dynamic control of the downforce provided to thesensor sled. In another example, magnetic downforce may be providedthrough a combination of a passive permanent magnet and an activeelectromagnet, providing a default minimum magnetic downforce, but withfurther increases available through the active electromagnet. Inembodiments, the electromagnet may be controlled by a circuit where thedownforce is set by the operator, controlled by an on-board processor,controlled by a remote processor (e.g., through wirelesscommunications), and the like, where processor control may utilizesensor data measurements to determine the downforce setting. Inembodiments, downforce may be provided through suction force, springforce, and the like. In certain embodiments, downforce may be providedby a biasing member, such as a torsion spring or leaf spring, withactive or passive control of the downforce—for example positioning atension or confinement of the spring to control the downforce. Incertain embodiments, the magnet, biasing member, or other downforceadjusting member may adjust the downforce on the entire sled 1, on anentire payload 2, and/or just on the sensor (e.g., the sensor has someflexibility to move within the sled 1, and the downforce adjustment actson the sensor directly).

An example system 100 includes an apparatus 800 (reference FIG. 8 andthe disclosure referencing FIG. 8) for providing enhanced inspectioninformation, including position-based information. The apparatus 800 andoperations to provide the position-based information are described inthe context of a particular physical arrangement of an industrial systemfor convenient illustration, however any physical arrangement of anindustrial system is contemplated herein. Referencing FIG. 5, an examplesystem includes a number of pipes 502—for example vertically arrangedpipes such as steam pipes in a power plant, pipes in a cooling tower,exhaust or effluent gas pipes, or the like. The pipes 502 in FIG. 5 arearranged to create a tower having a circular cross-section for ease ofdescription. In certain embodiments, periodic inspection of the pipes isutilized to ensure that pipe degradation is within limits, to ensureproper operation of the system, to determine maintenance and repairschedules, and/or to comply with policies or regulations. In the exampleof FIG. 5, an inspection surface 500 includes the inner portion of thetower, whereby an inspection robot 100 traverses the pipes 502 (e.g.,vertically, inspecting one or more pipes on each vertical run). Anexample inspection robot 100 includes configurable payloads 2, and mayinclude ultra-sonic sensors (e.g., to determine wall thickness and/orpipe integrity), magnetic sensors (e.g., to determine the presenceand/or thickness of a coating on a pipe), cameras (e.g., to provide forvisual inspection, including in EM ranges outside of the visual range,temperatures, etc.), composition sensors (e.g., gas chromatography inthe area near the pipe, spectral sensing to detect leaks or anomalousoperation, etc.), temperature sensing, pressure sensing (ambient and/orspecific pressures), vibration sensing, density sensing, etc. The typeof sensing performed by the inspection robot 100 is not limiting to thepresent disclosure except where specific features are described inrelation to specific sensing challenges and opportunities for thosesensed parameters as will be understood to one of skill in the arthaving the benefit of the disclosures herein.

In certain embodiments, the inspection robot 100 has alternatively oradditionally, payload(s) 2 configured to provide for marking of aspectsof the inspection surface 500 (e.g., a paint sprayer, an invisible or UVink sprayer, and/or a virtual marking device configured to mark theinspection surface 500 in a memory location of a computing device butnot physically), to repair a portion of the inspection surface 500(e.g., apply a coating, provide a welding operation, apply a temperaturetreatment, install a patch, etc.), and/or to provide for a cleaningoperation. Referencing FIG. 6, an example inspection robot 100 isdepicted in position on the inspection surface 500 at a location. In theexample, the inspection robot 100 traverses vertically and is positionedbetween two pipes 502, with payloads 2 configured to clean, sense,treat, and/or mark two adjacent pipes 502 in a single inspection run.The inspection robot 100 in the example includes two payloads 2 at the“front” (ahead of the robot housing in the movement direction) and twopayloads 2 at the “rear” (behind the robot housing in the movementdirection). The inspection robot 100 may include any arrangement ofpayloads 2, including just one or more payloads in front or behind, justone or more payloads off to either or both sides, and combinations ofthese. Additionally or alternatively, the inspection robot 100 may bepositioned on a single pipe, and/or may traverse between positionsduring an inspection operation, for example to inspect selected areas ofthe inspection surface 502 and/or to traverse obstacles which may bepresent.

In certain embodiments, a “front” payload 2 includes sensors configuredto determine properties of the inspection surface, and a “rear” payload2 includes a responsive payload, such as an enhanced sensor, a cleaningdevice such as a sprayer, scrubber, and/or scraper, a marking device,and/or a repair device. The front-back arrangement of payloads 2provides for adjustments, cleaning, repair, and/or marking of theinspection surface 502 in a single run—for example where an anomaly,gouge, weld line, area for repair, previously repaired area, pastinspection area, etc., is sensed by the front payload 2, the anomaly canbe marked, cleaned, repaired, etc. without requiring an additional runof the inspection robot 100 or a later visit by repair personnel. Inanother example, a first calibration of sensors for the front payloadmay be determined to be incorrect (e.g., a front ultra-sonic sensorcalibrated for a particular coating thickness present on the pipes 502)and a rear sensor can include an adjusted calibration to account for thedetected aspect (e.g., the rear sensor calibrated for the observedthickness of the coating). In another example, certain enhanced sensingoperations may be expensive, time consuming, consume more resources(e.g., a gamma ray source, an alternate coupling such as a non-water oroil-based acoustic coupler, require a high energy usage, require greaterprocessing resources, and/or incur usage charges to an inspection clientfor any reason) and the inspection robot 100 can thereby only utilizethe enhanced sensing operations selectively and in response to observedconditions.

Referencing FIG. 7, a location 702 on the inspection surface 500 isidentified for illustration. In certain embodiments, the inspectionrobot 100 and/or apparatus 800 includes a controller 802 having a numberof circuits structured to functionally execute operations of thecontroller 802. The controller 802 may be a single device (e.g., acomputing device present on the robot 100, a computing device incommunication with the robot 100 during operations and/orpost-processing information communicated after inspection operations,etc.) and/or a combination of devices, such as a portion of thecontroller 802 positioned on the robot 100, a portion of the controller802 positioned on a computing device in communication with the robot100, a portion of the controller 802 positioned on a handheld device(not shown) of an inspection operator, and/or a portion of thecontroller 802 positioned on a computing device networked with one ormore of the preceding devices. Additionally or alternatively, aspects ofthe controller 802 may be included on one or more logic circuits,embedded controllers, hardware configured to perform certain aspects ofthe controller 802 operations, one or more sensors, actuators, networkcommunication infrastructure (including wired connections, wirelessconnections, routers, switches, hubs, transmitters, and/or receivers),and/or a tether between the robot 100 and another computing device. Thedescribed aspects of the example controller 802 are non-limitingexamples, and any configuration of the robot 100 and devices incommunication with the robot 100 to perform all or selected ones ofoperations of the controller 802 are contemplated herein as aspects ofan example controller 802.

An example controller 802 includes an inspection data circuit 804 thatinterprets inspection data 812—for example sensed information fromsensors mounted on the payload and determining aspects of the inspectionsurface 500, the status, deployment, and/or control of marking devices,cleaning devices, and/or repair devices, and/or post-processedinformation from any of these such as a wall thickness determined fromultra-sonic data, temperature information determined from imaging data,and the like. The example controller 802 further includes a robotpositioning circuit 806 that interprets position data 814. An examplerobot positioning circuit 806 determines position data by any availablemethod, including at least triangulating (or other positioning methods)from a number of available wireless devices (e.g., routers available inthe area of the inspection surface 500, intentionally positionedtransmitters/transceivers, etc.), a distance of travel measurement(e.g., a wheel rotation counter which may be mechanical,electro-magnetic, visual, etc.; a barometric pressure measurement;direct visual determinations such as radar, Lidar, or the like), areference measurement (e.g., determined from distance to one or morereference points); a time-based measurement (e.g., based upon time andtravel speed); and/or a dead reckoning measurement such as integrationof detection movements. In the example of FIG. 5, a position measurementmay include a height determination combined with an azimuthal anglemeasurement and/or a pipe number value such that the inspection surface500 location is defined thereby. Any coordinate system and/or positiondescription system is contemplated herein. In certain embodiments, thecontroller 802 includes a processed data circuit 808 that combines theinspection data 812 with the position data 814 to determineposition-based inspection data. The operations of the processed datacircuit 808 may be performed at any time—for example during operationsof the inspection robot 100 such that inspection data 812 is stored withposition data 814, during a post-processing operation which may becompleted separately from the inspection robot 100, and/or which may beperformed after the inspection is completed, and/or which may becommenced while the inspection is being performed. In certainembodiments, the linking of the position data 814 with the inspectiondata 812 may be performed if the linked position-inspection data isrequested—for example upon a request by a client for an inspection map818. In certain embodiments, portions of the inspection data 812 arelinked to the position data 814 at a first time, and other portions ofthe inspection data 812 are linked to the position data 814 at a latertime and/or in response to post-processing operations, an inspection map818 request, or other subsequent event.

The example controller 802 further includes an inspection visualizationcircuit 810 that determines the inspection map 818 in response to theinspection data 812 and the position data 814, for example usingpost-processed information from the processed data circuit 808. In afurther example, the inspection visualization circuit 810 determines theinspection map 818 in response to an inspection visualization request820, for example from a client computing device 826. In the example, theclient computing device 826 may be communicatively coupled to thecontroller 802 over the internet, a network, through the operations of aweb application, and the like. In certain embodiments, the clientcomputing device 826 securely logs in to control access to theinspection map 818, and the inspection visualization circuit 810 mayprevent access to the inspection map 818, and/or provide only portionsof the inspection map 818, depending upon the successful login from theclient computing device 826, the authorizations for a given user of theclient computing device 826, and the like.

In certain embodiments, the inspection visualization circuit 810 and/orinspection data circuit 804 further accesses system data 816, such as atime of the inspection, a calendar date of the inspection, the robot 100utilized during the inspection and/or the configurations of the robot100, a software version utilized during the inspection, calibrationand/or sensor processing options selected during the inspection, and/orany other data that may be of interest in characterizing the inspection,that may be requested by a client, that may be required by a policyand/or regulation, and/or that may be utilized for improvement tosubsequent inspections on the same inspection surface 500 or anotherinspection surface. In certain embodiments, the processed data circuit808 combines the system data 816 with the processed data for theinspection data 812 and/or the position data 814, and/or the inspectionvisualization circuit incorporates the system data 816 or portionsthereof into the inspection map 818. In certain embodiments, any or allaspects of the inspection data 812, position data 814, and/or systemdata 816 may be stored as meta-data (e.g., not typically available fordisplay), may be accessible in response to prompts, further selections,and/or requests from the client computing device 826, and/or may beutilized in certain operations with certain identifiable aspects removed(e.g., to remove personally identifiable information or confidentialaspects) such as post-processing to improve future inspectionoperations, reporting for marketing or other purposes, or the like.

In certain embodiments, the inspection visualization circuit 810 isfurther responsive to a user focus value 822 to update the inspectionmap 818 and/or to provide further information (e.g., focus data 824) toa user, such as a user of the client computing device 826. For example,a user focus value 822 (e.g., a user mouse position, menu selection,touch screen indication, keystroke, or other user input value indicatingthat a portion of the inspection map 818 has received the user focus)indicates that a location 702 of the inspection map 818 has the userfocus, and the inspection visualization circuit 810 generates the focusdata 824 in response to the user focus value 822, including potentiallythe location 702 indicated by the user focus value 822.

Referencing FIG. 9, an example inspection map 818 is depicted. In theexample, the inspection surface 500 may be similar to that depicted inFIG. 5—for example the interior surface of tower formed by a number ofpipes to be inspected. The example inspection map 818 includes anazimuthal indication 902 and a height indication 904, with data from theinspection depicted on the inspection map 818 (e.g., shading at 906indicating inspection data corresponding to that visual location).Example and non-limiting inspection maps 818 include numeric valuesdepicted on the visualization, colors, shading or hatching, and/or anyother visual depiction method. In certain embodiments, more than oneinspection dimension may be visualized (e.g., temperatures and wallthickness), and/or the inspection dimension may be selected or changedby the user. Additionally or alternatively, physical elements such asobstacles, build up on the inspection surface, weld lines, gouges,repaired sections, photos of the location (e.g., the inspection map 818laid out over a panoramic photograph of the inspection surface 500 withdata corresponding to the physical location depicted), may be depictedwith or as a part of the inspection map 818. Additionally oralternatively, visual markers may be positioned on the inspection map818—for example a red “X” (or any other symbol, including a color,bolded area, highlight, image data, a thumbnail, etc.) at a location ofinterest on the map—which marking may be physically present on theactual inspection surface 500 or only virtually depicted on theinspection map 818. It can be seen that the inspection map 818 providesfor a convenient and powerful reference tool for a user to determine theresults of the inspection operation and plan for future maintenance,repair, or inspections, as well as planning logistics in response to thenumber of aspects of the system requiring further work or analysis andthe location of the aspects requiring further work or analysis.Accordingly, inspection results can be analyzed more quickly, regulatoryor policy approvals and system up-time can be restored more quickly (ifthe system was shut-down for the inspection), configurations of aninspection robot 100 for a future inspection can be performed morequickly (e.g. preparing payload 2 configurations, obstacle management,and/or sensor selection or calibration), any of the foregoing can beperformed with greater confidence that the results are reliable, and/orany combinations of the foregoing. Additionally or alternatively, lessinvasive operations can be performed, such as virtual marking whichwould not leave marks on the inspection surface 500 that might beremoved (e.g., accidentally) before they are acted upon, which mayremain after being acted upon, or which may create uncertainty as towhen the marks were made over the course of multiple inspections andmarking generations.

Referencing FIG. 10, an illustrative example inspection map 818 havingfocus data 824 is depicted. The example inspection map 818 is responsiveto a user focus value 822, such as a mouse cursor 1002 hovering over aportion of the inspection map 818. In the example, the focus data 824comes up as a tool-tip, although any depiction operations such as outputto a file, populating a static window for focus data 824, or any otheroperations known in the art are contemplated herein. The example focusdata 824 includes a date (e.g., of the inspection), a time (e.g., of theinspection), the sensor calibrations utilized for the inspection, andthe time to repair (e.g., down-time that would be required, actualrepair time that would be required, the estimated time until the portionof the inspection surface 500 will require a repair, or any otherdescription of a “time to repair”). The depicted focus data 824 is anon-limiting example, and any other information of interest may beutilized as focus data 824. In certain embodiments, a user may selectthe information, or portions thereof, utilized on the inspection map818—including at least the axes 902, 904 (e.g., units, type ofinformation, relative versus absolute data, etc.) and the depicted data(e.g., units, values depicted, relative versus absolute values,thresholds or cutoffs of interest, processed values such as virtuallydetermined parameters, and/or categorical values such as “PASSED” or“FAILED”). Additionally or alternatively, a user may select theinformation, or portions thereof, utilized as the focus data 824.

In certain embodiments, an inspection map 818 (or display) provides anindication of how long a section of the inspection surface 500 isexpected to continue under nominal operations, how much material shouldbe added to a section of the inspection surface 500 (e.g., a repaircoating or other material), and/or the type of repair that is needed(e.g., wall thickness correction, replacement of a coating, fixing ahole, breach, rupture, etc.).

Referencing FIG. 41, an apparatus 4100 for determining a facility wearvalue 4106 is depicted. The example apparatus 4100 includes a facilitywear circuit 4102 that determines a facility wear model 4104corresponding to the inspection surface 500 and/or an industrialfacility, industrial system, and/or plant including the inspectionsurface 500. An example facility wear circuit 4102 accesses a facilitywear model 4104, and utilizes the inspection data 812 to determine whichportions of the inspection surface 500 will require repair, when theywill require repair, what type of repair will be required, and afacility wear value 4106 including a description of how long theinspection surface 500 will last without repair, and/or with selectedrepairs. In certain embodiments, the facility wear model 4104 includeshistorical data for the particular facility, system, or plant having theinspection surface 500—for example through empirical observation ofprevious inspection data 812, when repairs were performed, what types ofrepairs were performed, and/or how long repaired sections lasted afterrepairs.

Additionally or alternatively, the facility wear model 4104 includesdata from offset facilities, systems, or plants (e.g., a similar systemthat operates a similar duty cycle of relevant temperatures, materials,process flow streams, vibration environment, etc. for the inspectionsurface 500; and which may include inspection data, repair data, and/oroperational data from the offset system), canonical data (e.g.,pre-entered data based on estimates, modeling, industry standards, orother indirect sources), data from other facilities from the same dataclient (e.g., an operator, original equipment manufacturer, owner, etc.for the inspection surface), and/or user-entered data (e.g., from aninspection operator and/or client of the data) such as assumptions to beutilized, rates of return for financial parameters, policies orregulatory values, and/or characterizations of experience in similarsystems that may be understood based on the experience of the user.Accordingly, operations of the facility wear circuit 4102 can provide anoverview of repair operations recommended for the inspection surface500, including specific time frame estimates of when such repairs willbe required, as well as a number of options for repair operations andhow long they will last.

In certain embodiments, the facility wear value 4106, and/or facilitywear value 4106 displayed on an inspection map 818, allows for strategicplanning of repair operations, and/or coordinating the life cycle of thefacility including the inspection surface 500—for example performing ashort-term repair at a given time, which might not be intuitively the“best” repair operation, but in view of a larger repair cycle that isupcoming for the facility. Additionally or alternatively, we facilitywear value 4106 allows for a granular review of the inspection surface500—for example to understand operational conditions that drive highwear, degradation, and/or failure conditions of aspects of theinspection surface 500. In certain embodiments, repair data and/or thefacility wear value 4106 are provided in a context distinct from aninspection map 818—for example as part of an inspection report (notshown), as part of a financial output related to the system having theinspection surface (e.g., considering the costs and shutdown timesimplicated by repairs, and/or risks associated with foregoing a repair).

Referencing FIG. 42, a procedure 4200 for determining a facility wearvalue is depicted schematically. An example procedure 4200 includes anoperation 4202 to interpret inspection data for an inspection surface,and an operation 4204 to access a facility wear model. The exampleprocedure 4200 further includes an operation 4206 to determine afacility wear value in response to the inspection data and the facilitywear model. The example procedure 4200 further includes an operation4208 to provide the facility wear value—for example as a portion of aninspection map, an inspection report, and/or a financial report for afacility having the inspection surface.

In embodiments, the robotic vehicle may incorporate a number of sensorsdistributed across a number of sensor sleds 1, such as with a singlesensor mounted on a single sensor sled 1, a number of sensors mounted ona single sensor sled 1, a number of sensor sleds 1 arranged in a linearconfiguration perpendicular to the direction of motion (e.g.,side-to-side across the robotic vehicle), arranged in a linearconfiguration along the direction of motion (e.g., multiple sensors on asensor sled 1 or multiple sensor sleds 1 arranged to cover the samesurface location one after the other as the robotic vehicle travels).Additionally or alternatively, a number of sensors may be arranged in atwo-dimensional surface area, such as by providing sensor coverage in adistributed manner horizontally and/or vertically (e.g., in thedirection of travel), including offset sensor positions (e.g., referenceFIG. 14). In certain embodiments, the utilization of payloads 2 withsensor sleds mounted thereon enables rapid configuration of sensorplacement as desired, sleds 1 on a given payload 2 can be furtheradjusted, and/or sensor(s) on a given sled can be changed or configuredas desired.

In certain embodiments, two payloads 2 side-by-side allow for a widehorizontal coverage of sensing for a given travel of the inspectionrobot 100—for example as depicted in FIG. 1. In certain embodiments, apayload 2 is coupled to the inspection robot 100 with a pin or otherquick-disconnect arrangement, allowing for the payload 2 to be removed,to be reconfigured separately from the inspection robot 100, and/or tobe replaced with another payload 2 configured in a desired manner. Thepayload 2 may additionally have a couplant connection to the inspectionrobot 100 (e.g., reference FIG. 29—where a single couplant connectionprovides coupling connectivity to all sleds 1A and 1B) and/or anelectrical connection to the inspection robot 100. Each sled may includea couplant connection conduit where the couplant connection conduit iscoupled to a payload couplant connection at the upstream end and iscoupled to the couplant entry of the cone at the downstream end.Multiple payload couplant connections on a single payload may be coupledtogether to form a single couplant connection between the payload andthe inspection robot. The single couplant connection per payloadfacilitates the changing of the payload without having toconnect/disconnect the couplant line connections at each sled. Thecouplant connection conduit between the payload couplant connection andthe couplant entry of the cone facilitates connecting/disconnecting asled from a payload without having to connect/disconnect the couplantconnection conduit from the couplant entry of the cone. The couplantand/or electrical connections may include power for the sensors asrequired, and/or communication coupling (e.g., a datalink or networkconnection). Additionally or alternatively, sensors may communicatewirelessly to the inspection robot 100 or to another computing device,and/or sensors may store data in a memory associated with the sensor,sled 1, or payload 2, which may be downloaded at a later time. Any otherconnection type required for a payload 2, such as compressed air, paint,cleaning solutions, repair spray solutions, or the like, may similarlybe coupled from the payload 2 to the inspection robot 100.

The horizontal configuration of sleds 1 (and sensors) is selectable toachieve the desired inspection coverage. For example, sleds 1 may bepositioned to provide a sled running on each of a selected number ofpipes of an inspection surface, positioned such that several sleds 1combine on a single pipe of an inspection surface (e.g., providinggreater radial inspection resolution for the pipe), and/or at selectedhorizontal distances from each other (e.g., to provide 1 inchresolution, 2 inch resolution, 3 inch resolution, etc.). In certainembodiments, the degrees of freedom of the sensor sleds 1 (e.g., frompivots 16, 17, 18) allow for distributed sleds 1 to maintain contact andorientation with complex surfaces.

In certain embodiments, sleds 1 are articulable to a desired horizontalposition. For example, quick disconnects may be provided (pins, claims,set screws, etc.) that allow for the sliding of a sled 1 to any desiredlocation on a payload 2, allowing for any desired horizontal positioningof the sleds 1 on the payload 2. Additionally or alternatively, sleds 1may be movable horizontally during inspection operations. For example, aworm gear or other actuator may be coupled to the sled 1 and operable(e.g., by a controller 802) to position the sled 1 at a desiredhorizontal location. In certain embodiments, only certain ones of thesleds 1 are moveable during inspection operations—for example outersleds 1 for maneuvering past obstacles. In certain embodiments, all ofthe sleds 1 are moveable during inspection operations—for example tosupport arbitrary inspection resolution (e.g., horizontal resolution,and/or vertical resolution), to configure the inspection trajectory ofthe inspection surface, or for any other reason. In certain embodiments,the payload 2 is horizontally moveable before or during inspectionoperations. In certain embodiments, an operator configures the payload 2and/or sled 1 horizontal positions before inspection operations (e.g.,before or between inspection runs). In certain embodiments, an operatoror a controller 802 configures the payload 2 and/or sled 1 horizontalpositions during inspection operations. In certain embodiments, anoperator can configure the payload 2 and/or sled 1 horizontal positionsremotely, for example communicating through a tether or wirelessly tothe inspection robot.

The vertical configuration of sleds 1 is selectable to achieve thedesired inspection coverage (e.g., horizontal resolution, verticalresolution, and/or redundancy). For example, referencing FIG. 13,multiple payloads 2 are positioned on a front side of the inspectionrobot 100, with forward payloads 2006 and rear payloads 1402. In certainembodiments, a payload 2 may include a forward payload 2006 and a rearpayload 1402 in a single hardware device (e.g., with a single mountingposition to the inspection robot 100), and/or may be independentpayloads 2 (e.g., with a bracket extending from the inspection robot 100past the rear payload 1402 for mounting the forward payloads 2006). Inthe example of FIG. 13, the rear payload 1402 and front payload 2006include sleds 1 mounted thereupon which are in vertical alignment1302—for example a given sled 1 of the rear payload 1402 traverses thesame inspection position (or horizontal lane) of a corresponding sled 1of the forward payload 2006. The utilization of aligned payloads 2provides for a number of capabilities for the inspection robot 100,including at least: redundancy of sensing values (e.g., to develophigher confidence in a sensed value); the utilization of more than onesensing calibration for the sensors (e.g., a front sensor utilizes afirst calibration set, and a rear sensor utilizes a second calibrationset); the adjustment of sensing operations for a rear sensor relative toa forward sensor (e.g., based on the front sensed parameter, a rearsensor can operate at an adjusted range, resolution, sampling rate, orcalibration); the utilization of a rear sensor in response to a frontsensor detected value (e.g., a rear sensor may be a high costsensor—either high power, high computing/processing requirements, anexpensive sensor to operate, etc.) where the utilization of the rearsensor can be conserved until a front sensor indicates that a value ofinterest is detected; the operation of a repair, marking, cleaning, orother capability rear payload 1402 that is responsive to the detectedvalues of the forward payload 2006; and/or for improved verticalresolution of the sensed values (e.g., if the sensor has a givenresolution of detection in the vertical direction, the front and rearpayloads can be operated out of phase to provide for improved verticalresolution).

In another example, referencing FIG. 14, multiple payloads 2 arepositioned on the front of the inspection robot 100, with sleds 1mounted on the front payload 2006 and rear payload 1402 that are notaligned (e.g., lane 1304 is not shared between sleds of the frontpayload 2006 and rear payload 2002). The utilization of not alignedpayloads 2 allows for improved resolution in the horizontal directionfor a given number of sleds 1 mounted on each payload 2. In certainembodiments, not aligned payloads may be utilized where the hardwarespace on a payload 2 is not sufficient to conveniently provide asufficient number or spacing of sleds 1 to achieve the desiredhorizontal coverage. In certain embodiments, not aligned payloads may beutilized to limit the number of sleds 1 on a given payload 2, forexample to provide for a reduced flow rate of couplant through a givenpayload-inspection robot connection, to provide for a reduced load on anelectrical coupling (e.g., power supply and/or network communicationload) between a given payload and the inspection robot. While theexamples of FIGS. 13 and 14 depict aligned or not aligned sleds forconvenience of illustration, a given inspection robot 100 may beconfigured with both aligned and not aligned sleds 1, for example toreduce mechanical loads, improve inspection robot balance, in responseto inspection surface constraints, or the like.

It can be seen that sensors may be modularly configured on the roboticvehicle to collect data on specific locations across the surface oftravel (e.g., on a top surface of an object, on the side of an object,between objects, and the like), repeat collection of data on the samesurface location (e.g., two sensors serially collecting data from thesame location, either with the same sensor type or different sensortypes), provide predictive sensing from a first sensor to determine if asecond sensor should take data on the same location at a second timeduring a single run of the robotic vehicle (e.g., an ultra-sonic sensormounted on a leading sensor sled taking data on a location determinesthat a gamma-ray measurement should be taken for the same location by asensor mounted on a trailing sensor sled configured to travel over thesame location as the leading sensor), provide redundant sensormeasurements from a plurality of sensors located in leading and trailinglocations (e.g., located on the same or different sensor sleds to repeatsensor data collection), and the like.

In certain embodiments, the robotic vehicle includes sensor sleds withone sensor and sensor sleds with a plurality of sensors. A number ofsensors arranged on a single sensor sled may be arranged with the samesensor type across the direction of robotic vehicle travel (e.g.,perpendicular to the direction of travel, or “horizontal”) to increasecoverage of that sensor type (e.g., to cover different surfaces of anobject, such as two sides of a pipe), arranged with the same sensor typealong the direction of robotic vehicle travel (e.g., parallel to thedirection of travel, or “vertical”) to provide redundant coverage ofthat sensor type over the same location (e.g., to ensure data coverage,to enable statistical analysis based on multiple measurements over thesame location), arranged with a different sensor type across thedirection of robotic vehicle travel to capture a diversity of sensordata in side-by-side locations along the direction of robotic vehicletravel (e.g., providing both ultra-sonic and conductivity measurementsat side-by-side locations), arranged with a different sensor type alongthe direction of robotic vehicle travel to provide predictive sensingfrom a leading sensor to a trailing sensor (e.g., running a trailinggamma-ray sensor measurement only if a leading ultra-sonic sensormeasurement indicates the need to do so), combinations of any of these,and the like. The modularity of the robotic vehicle may permitexchanging sensor sleds with the same sensor configuration (e.g.,replacement due to wear or failure), different sensor configurations(e.g., adapting the sensor arrangement for different surfaceapplications), and the like.

Providing for multiple simultaneous sensor measurements over a surfacearea, whether for taking data from the same sensor type or fromdifferent sensor types, provides the ability to maximize the collectionof sensor data in a single run of the robotic vehicle. If the surfaceover which the robotic vehicle was moving were perfectly flat, thesensor sled could cover a substantial surface with an array of sensors.However, the surface over which the robotic vehicle travels may behighly irregular, and have obstacles over which the sensor sleds mustadjust, and so the preferred embodiment for the sensor sled isrelatively small with a highly flexible orientation, as describedherein, where a plurality of sensor sleds is arranged to cover an areaalong the direction of robotic vehicle travel. Sensors may bedistributed amongst the sensor sleds as described for individual sensorsleds (e.g., single sensor per sensor sled, multiple sensors per sensorsled (arranged as described herein)), where total coverage is achievedthrough a plurality of sensor sleds mounted to the robotic vehicle. Onesuch embodiment, as introduced herein, such as depicted in FIG. 1,comprises a plurality of sensor sleds arranged linearly across thedirection of robotic vehicle travel, where the plurality of sensor sledsare capable of individually adjusting to the irregular surface as therobotic vehicle travels. Further, each sensor sled may be positioned toaccommodate regular characteristics in the surface (e.g., positioningsensor sleds to ride along a selected portion of a pipe aligned alongthe direction of travel), to provide for multiple detections of a pipeor tube from a number of radial positions, sensor sleds may be shaped toaccommodate the shape of regular characteristics in the surface (e.g.,rounded surface of a pipe), and the like. In this way, the sensor sledarrangement may accommodate both the regular characteristics in thesurface (e.g., a series of features along the direction of travel) andirregular characteristics along the surface (e.g., obstacles that thesensor sleds flexibly mitigate during travel along the surface).

Although FIG. 1 depicts a linear arrangement of sensor sleds with thesame extension (e.g., the same connector arm length), another examplearrangement may include sensor sleds with different extensions, such aswhere some sensor sleds are arranged to be positioned further out,mounted on longer connection arms. This arrangement may have theadvantage of allowing a greater density of sensors across theconfiguration, such as where a more leading sensor sled could bepositioned linearly along the configuration between two more trailingsensor sleds such that sensors are provided greater linear coverage thanwould be possible with all the sensor sleds positioned side-by-side.This configuration may also allow improved mechanical accommodationbetween the springs and connectors that may be associated withconnections of sensor sleds to the arms and connection assembly (e.g.,allowing greater individual movement of sensor sleds without the sensorsleds making physical contact with one another).

Referring to FIG. 13, an example configuration of sensor sleds includesthe forward sensor sled array 2006 ahead of the rear sled array 1402,such as where each utilizes a sensor sled connector assembly 2004 formounting the payloads. Again, although FIG. 13 depicts the sensor sledsarranged on the sensor sled connector assembly 2004 with equal lengtharms, different length arms may be utilized to position, for instance,sensor sleds of sensor sled array 1402 in intermediate positions betweenrear sensor sleds of rear payload 1402 and forward sensor sleds of theforward payload 2006. As was the case with the arrangement of aplurality of sensors on a single sensor sled to accommodate differentcoverage options (e.g., maximizing coverage, predictive capabilities,redundancy, and the like), the extended area configuration of sensors inthis multiple sensor sled array arrangement allows similarfunctionality. For instance, a sensor sled positioned in a lateralposition on the forward payload 2006 may provide redundant or predictivefunctionality for another sensor sled positioned in the same lateralposition on the rear payload 1402. In the case of a predictivefunctionality, the greater travel distance afforded by the separationbetween a sensor sled mounted on the second sensor sled array 2006 andthe sensor sled array 1402 may provide for additional processing timefor determining, for instance, whether the sensor in the trailing sensorsled should be activated. For example, the leading sensor collectssensor data and sends that data to a processing function (e.g., wiredcommunication to on-board or external processing, wireless communicationto external processing), the processor takes a period of time todetermine if the trailing sensor should be activated, and after thedetermination is made, activates the trailing sensor. The separation ofthe two sensors, divided by the rate of travel of the robotic vehicle,determines the time available for processing. The greater the distance,the greater the processing time allowed. Referring to FIG. 15, inanother example, distance is increased further by utilizing a trailingpayload 2008, thus increasing the distance and processing time further.Additionally or alternatively, the hardware arrangement of FIG. 15 mayprovide for more convenient integration of the trailing payload 2008rather than having multiple payloads 1402, 2006 in front of theinspection robot 100. In certain embodiments, certain operations of apayload 2 may be easier or more desirable to perform on a trailing sideof the inspection robot 100—such as spraying of painting, marking, orrepair fluids, to avoid the inspection robot 100 having to be exposed tosuch fluids as a remaining mist, by gravity flow, and/or having to drivethrough the painted, cleaned, or repaired area. In certain embodiments,an inspection robot 100 may additionally or alternatively include bothmultiple payloads 1402, 2006 in front of the inspection robot (e.g., asdepicted in FIGS. 13 and 14) and/or one or more trailing payloads (e.g.,as depicted in FIG. 15).

In another example, the trailing sensor sled array 2008 may provide agreater distance for functions that would benefit the system by beingisolated from the sensors in the forward end of the robotic vehicle. Forinstance, the robotic vehicle may provide for a marking device (e.g.,visible marker, UV marker, and the like) to mark the surface when acondition alert is detected (e.g., detecting corrosion or erosion in apipe at a level exceeding a predefined threshold, and marking the pipewith visible paint).

Embodiments with multiple sensor sled connector assemblies provideconfigurations and area distribution of sensors that may enable greaterflexibility in sensor data taking and processing, including alignment ofsame-type sensor sleds allowing for repeated measurements (e.g., thesame sensor used in a leading sensor sled as in a trailing sensor sled,such as for redundancy or verification in data taking when leading andtrailing sleds are co-aligned), alignment of different-type sensor sledsfor multiple different sensor measurements of the same path (e.g.,increase the number of sensor types taking data, have the lead sensorprovide data to the processor to determine whether to activate thetrailing sensor (e.g., ultra-sonic/gamma-ray, and the like)), off-setalignment of same-type sensor sleds for increased coverage when leadingand trailing sleds are off-set from one another with respect to travelpath, off-set alignment of different-type sensor sleds for trailingsensor sleds to measure surfaces that have not been disturbed by leadingsensor sleds (e.g., when the leading sensor sled is using a couplant),and the like.

The modular design of the robotic vehicle may provide for a systemflexible to different applications and surfaces (e.g., customizing therobot and modules of the robot ahead of time based on the application,and/or during an inspection operation), and to changing operationalconditions (e.g., flexibility to changes in surface configurations andconditions, replacement for failures, reconfiguration based on sensedconditions), such as being able to change out sensors, sleds, assembliesof sleds, number of sled arrays, and the like.

An example inspection robot utilizes a magnet-based wheel design (e.g.,reference FIG. 2 and the related description). Although the inspectionrobot may utilize flux directing ferromagnetic wheel components, such asferromagnetic magnet enclosures 3 to minimize the strength of theextended magnetic field, ferromagnetic components within the inspectionrobot may be exposed to a magnetic field. One component that mayexperience negative effects from the magnetic field is the gearbox,which may be mounted proximate to the wheel assembly. FIG. 12illustrates an example gearbox configuration, showing the direction 2083of magnetic attraction axially along the drive shaft to the wheel (wheelnot shown). The magnetic attraction, acting on, in this instance,ferromagnetic gears, results in an axial load applied to the gears,pulling the gears against the gear carrier plates 2082 with forces thatthe gears would otherwise not experience. This axial load may result inincreased friction, heat, energy loss, and wear.

Referencing FIG. 12, an example arrangement depicts the inclusion ofwear-resistant thrust washers 2084, placed to provide a reducedfrictional interface between the gears and the adjacent surface. Thus,the negative effects of the axial load are minimized without significantchanges to a gearbox design. In a second example, with wheels onopposing sides of the gear box assembly(s), the gearbox configuration ofthe inspection robot may be spatially arranged such that the netmagnetic forces acting on the gears are largely nullified, that is,balanced between forces from a wheel magnet on one side and a secondwheel magnet on the other side. Careful layout of the gearboxconfiguration could thus reduce the net forces acting on the gears. Inembodiments, example one and example two may be applied alone or incombination. For instance, the gearbox configuration may be spatiallyarranged to minimize the net magnetic forces acting on gears, wherethrust washers are applied to further reduce the negative effects of anyremaining net magnetic forces. In a third example, the negative effectsupon the gearbox resulting from magnetic fields may be eliminated bymaking the gears from non-ferrous materials. Example and non-limitingexamples of non-ferrous materials include polyoxymethylene (e.g.,Delrin® acetyl resin, etc.), a low- or non-magnetic steel (e.g. 316stainless steel or 304 stainless steel), and/or aluminum (e.g., 2024Al). In certain embodiments, other materials such as ceramic, nylon,copper, or brass may be used for gears, depending upon the wear and loadrequirements of the gearbox, the potential intrusion of water to thegearbox, and/or the acceptable manufacturing costs and tolerances.

Throughout the present description, certain orientation parameters aredescribed as “horizontal,” “perpendicular,” and/or “across” thedirection of travel of the inspection robot, and/or described as“vertical,” “parallel,” and/or in line with the direction of travel ofthe inspection robot. It is specifically contemplated herein that theinspection robot may be travelling vertically, horizontally, at obliqueangles, and/or on curves relative to a ground-based absolute coordinatesystem. Accordingly, except where the context otherwise requires, anyreference to the direction of travel of the inspection robot isunderstood to include any orientation of the robot—such as an inspectionrobot traveling horizontally on a floor may have a “vertical” directionfor purposes of understanding sled distribution that is in a“horizontal” absolute direction. Additionally, the “vertical” directionof the inspection robot may be a function of time during inspectionoperations and/or position on an inspection surface—for example as aninspection robot traverses over a curved surface. In certainembodiments, where gravitational considerations or other context basedaspects may indicate—vertical indicates an absolute coordinate systemvertical—for example in certain embodiments where couplant flow into acone is utilized to manage bubble formation in the cone. In certainembodiments, a trajectory through the inspection surface of a given sledmay be referenced as a “horizontal inspection lane”—for example, thetrack that the sled takes traversing through the inspection surface.

Certain embodiments include an apparatus for acoustic inspection of aninspection surface with arbitrary resolution. Arbitrary resolution, asutilized herein, includes resolution of features in geometric space witha selected resolution—for example resolution of features (e.g., cracks,wall thickness, anomalies, etc.) at a selected spacing in horizontalspace (e.g., perpendicular to a travel direction of an inspection robot)and/or vertical space (e.g., in a travel direction of an inspectionrobot). While resolution is described in terms of the travel motion ofan inspection robot, resolution may instead be considered in anycoordinate system, such as cylindrical or spherical coordinates, and/oralong axes unrelated to the motion of an inspection robot. It will beunderstood that the configurations of an inspection robot and operationsdescribed in the present disclosure can support arbitrary resolution inany coordinate system, with the inspection robot providing sufficientresolution as operated, in view of the target coordinate system.Accordingly, for example, where inspection resolution of 6-inches isdesired in a target coordinate system that is diagonal to the traveldirection of the inspection robot, the inspection robot and relatedoperations described throughout the present disclosure can supportwhatever resolution is required (whether greater than 6-inches, lessthan 6-inches, or variable resolution depending upon the location overthe inspection surface) to facilitate the 6-inch resolution of thetarget coordinate system. It can be seen that an inspection robot and/orrelated operations capable of achieving an arbitrary resolution in thecoordinates of the movement of the inspection robot can likewise achievearbitrary resolution in any coordinate system for the mapping of theinspection surface. For clarity of description, apparatus and operationsto support an arbitrary resolution are described in view of thecoordinate system of the movement of an inspection robot.

An example apparatus to support acoustic inspection of an inspectionsurface includes an inspection robot having a payload and a number ofsleds mounted thereon, with the sleds each having at least one acousticsensor mounted thereon. Accordingly, the inspection robot is capable ofsimultaneously determining acoustic parameters at a range of positionshorizontally. Sleds may be positioned horizontally at a selectedspacing, including providing a number of sleds to provide sensorspositioned radially around several positions on a pipe or other surfacefeature of the inspection surface. In certain embodiments, verticalresolution is supported according to the sampling rate of the sensors,and/or the movement speed of the inspection robot. Additionally oralternatively, the inspection robot may have vertically displacedpayloads, having an additional number of sleds mounted thereon, with thesleds each having at least one acoustic sensor mounted thereon. Theutilization of additional vertically displaced payloads can provideadditional resolution, either in the horizontal direction (e.g., wheresleds of the vertically displaced payload(s) are offset from sleds inthe first payload(s)) and/or in the vertical direction (e.g., wheresensors on sleds of the vertically displaced payload(s) are samplingsuch that sensed parameters are vertically offset from sensors on sledsof the first payload(s)). Accordingly, it can be seen that, even wherephysical limitations of sled spacing, numbers of sensors supported by agiven payload, or other considerations limit horizontal resolution for agiven payload, horizontal resolution can be enhanced through theutilization of additional vertically displaced payloads. In certainembodiments, an inspection robot can perform another inspection run overa same area of the inspection surface, for example with sleds trackingin an offset line from a first run, with positioning information toensure that both horizontal and/or vertical sensed parameters are offsetfrom the first run.

Accordingly, an apparatus is provided that achieves significantresolution improvements, horizontally and/or vertically, over previouslyknown systems. Additionally or alternatively, an inspection robotperforms inspection operations at distinct locations on a descentoperation than on an ascent operation, providing for additionalresolution improvements without increasing a number of run operationsrequired to perform the inspection (e.g., where an inspection robotascends an inspection surface, and descends the inspection surface as anormal part of completing the inspection run). In certain embodiments,an apparatus is configured to perform multiple run operations to achievethe selected resolution. It can be seen that the greater the number ofinspection runs required to achieve a given spatial resolution, thelonger the down time for the system (e.g., an industrial system) beinginspected (where a shutdown of the system is required to perform theinspection), the longer the operating time and greater the cost of theinspection, and/or the greater chance that a failure occurs during theinspection. Accordingly, even where multiple inspection runs arerequired, a reduction in the number of the inspection runs isbeneficial.

In certain embodiments, an inspection robot includes a low fluid losscouplant system, enhancing the number of sensors that are supportable ina given inspection run, thereby enhancing available sensing resolution.In certain embodiments, an inspection robot includes individual downforce support for sleds and/or sensors, providing for reduced fluidloss, reduced off-nominal sensing operations, and/or increasing theavailable number of sensors supportable on a payload, thereby enhancingavailable sensing resolution. In certain embodiments, an inspectionrobot includes a single couplant connection for a payload, and/or asingle couplant connection for the inspection robot, thereby enhancingreliability and providing for a greater number of sensors on a payloadand/or on the inspection robot that are available for inspections undercommercially reasonable operations (e.g., configurable for inspectionoperations with reasonable reliability, checking for leaks, expected tooperate without problems over the course of inspection operations,and/or do not require a high level of skill or expensive test equipmentto ensure proper operation). In certain embodiments, an inspection robotincludes acoustic sensors coupled to acoustic cones, enhancing robustdetection operations (e.g., a high percentage of valid sensing data,ease of acoustic coupling of a sensor to an inspection surface, etc.),reducing couplant fluid losses, and/or easing integration of sensorswith sleds, thereby supporting an increased number of sensors perpayload and/or inspection robot, and enhancing available sensingresolution. In certain embodiments, an inspection robot includesutilizing water as a couplant, thereby reducing fluid pumping losses,reducing risks due to minor leaks within a multiple plumbing line systemto support multiple sensors, and/or reducing the impact (environmental,hazard, clean-up, etc.) of performing multiple inspection runs and/orperforming an inspection operation with a multiplicity of acousticsensors operating.

Referencing FIG. 33, an example procedure 3300 to acoustically inspectan inspection surface with an arbitrary (or selectable) resolution isschematically depicted. The example procedure 3300 includes an operation3302 to determine a desired resolution of inspection for the surface.The operation 3302 includes determining the desired resolution inwhatever coordinate system is considered for the inspection surface, andtranslating the desired resolution for the coordinate system of theinspection surface to a coordinate system of an inspection robot (e.g.,in terms of vertical and horizontal resolution for the inspectionrobot), if the coordinate system for the inspection surface is distinctfrom the coordinate system of the inspection robot. The exampleprocedure 3300 further includes an operation 3304 to provide aninspection robot in response to the desired resolution of inspection,the inspection robot having at least one payload, a number of sledsmounted on the payload, and at least one acoustic sensor mounted on eachsled. It will be understood that certain sleds on the payload may nothave an acoustic sensor mounted thereupon, but for provision of selectedacoustic inspection resolution, only the sleds having an acoustic sensormounted thereupon are considered. In certain embodiments, operation 3304additionally or alternatively includes one or more operations such as:providing multiple payloads; providing vertically displaced payloads;providing offset sleds on one or more vertically displaced payloads;providing payloads having a single couplant connection for the payload;providing an inspection robot having a single couplant connection forthe inspection robot; providing an inspection robot utilizing water as acouplant; providing a down force to the sleds to ensure alignment and/orreduced fluid loss; providing degrees of freedom of movement to thesleds to ensure alignment and/or robust obstacle traversal; providingthe sensors coupled to an acoustic cone; and/or configuring a horizontalspacing of the sleds in response to the selected resolution (e.g.,spaced to support the selected resolution, spaced to support theselected resolution between an ascent and a descent, and/or spaced tosupport the selected resolution with a scheduled number of inspectionruns).

The example procedure 3300 further includes an operation 3306 to performan inspection operation of an inspection surface with arbitraryresolution. For example, operation 3306 includes at least: operating thenumber of horizontally displaced sensors to achieve the arbitraryresolution; operating vertically displaced payloads in a scheduledmanner (e.g., out of phase with the first payload thereby inspecting avertically distinct set of locations of the inspection surface);operating vertically displaced payloads to enhance horizontal inspectionresolution; performing an inspection on a first horizontal track on anascent, and a second horizontal track distinct from the first horizontaltrack on a descent; performing an inspection on a first vertical set ofpoints on an ascent, and on a second vertical set of points on a descent(which may be on the same or a distinct horizontal track); and/orperforming a plurality of inspection runs where the horizontal and/orvertical inspection positions of the multiple runs are distinct from thehorizontal and/or vertical inspection positions of a first run. Certainoperations of the example procedure 3300 may be performed by acontroller 802.

While operations of procedure 3300, and an apparatus to provide forarbitrary or selected resolution inspections of a system are describedin terms of acoustic sensing, it will be understood that arbitrary orselected resolution of other sensed parameters are contemplated herein.In certain embodiments, acoustic sensing provides specific challengesthat are addressed by certain aspects of the present disclosure.However, sensing of any parameter, such as temperature, magnetic orelectro-magnetic sensing, infra-red detection, UV detection, compositiondeterminations, and other sensed parameters also present certainchallenges addressed by certain aspects of the present disclosure. Forexample, the provision of multiple sensors in a single inspection run atdeterminable locations, the utilization of an inspection robot (e.g.,instead of a person positioned in the inspection space), including aninspection robot with position sensing, and/or the reduction of sensorinterfaces including electrical and communication interfaces, providesfor ease of sensing for any sensed parameters at a selected resolution.In certain embodiments, a system utilizes apparatuses and operationsherein to achieve arbitrary resolution for acoustic sensing. In certainembodiments, a system additionally or alternatively utilizes apparatusesand operations herein to achieve arbitrary resolution for any sensedparameter.

Referencing FIG. 34, an example apparatus 3400 is depicted forconfiguring a trailing sensor inspection scheme in response to a leadingsensor inspection value. The example apparatus 3400 includes acontroller 802 having an inspection data circuit 804 that interpretslead inspection data 3402 from a lead sensor. Example and non-limitinglead sensors include a sensor mounted on a sled of a forward payload2006, a sensor mounted on either a forward payload 2006 or a rearpayload 1402 of an inspection robot having a trailing payload 2008,and/or a sensor operated on a first run of an inspection robot, whereoperations of the apparatus 3400 proceed with adjusting operations of asensor on a subsequent run of the inspection robot (e.g., the first runis ascending, and the subsequent run is descending; the first run isdescending, and the subsequent run is ascending; and/or the first run isperformed at a first time, and the subsequent run is performed at asecond, later, time).

The example controller 802 further includes a sensor configurationcircuit 3404 structured to determine a configuration adjustment 3406 fora trailing sensor. Example and non-limiting trailing sensors include anysensor operating over the same or a substantially similar portion of theinspection surface as the lead sensor, at a later point in time. Atrailing sensor may be a sensor positioned on a payload behind thepayload having the lead sensor, a physically distinct sensor from thelead sensor operating over the same or a substantially similar portionof the inspection surface after the lead sensor, and/or a sensor that isphysically the same sensor as the lead sensor, but reconfigured in someaspect (e.g., sampling parameters, calibrations, inspection robot rateof travel change, etc.). A portion that is substantially similarincludes a sensor operating on a sled in the same horizontal track(e.g., in the direction of inspection robot movement) as the leadsensor, a sensor that is sensing a portion of the inspection sensor thatis expected to determine the same parameters (e.g., wall thickness in agiven area) of the inspection surface as that sensed by the lead sensor,and/or a sensor operating in a space of the inspection area where it isexpected that determinations for the lead sensor would be effective inadjusting the trailing sensor. Example and non-limiting determinationsfor the lead sensor to be effective in adjusting the trailing sensorinclude pipe thickness determinations for a same pipe and/or samecooling tower, where pipe thickness expectations may affect thecalibrations or other settings utilized by the lead and trailingsensors; determination of a coating thickness where the trailing sensoroperates in an environment that has experienced similar conditions(e.g., temperatures, flow rates, operating times, etc.) as theconditions experienced by the environment sensed by the lead sensor;and/or any other sensed parameter affecting the calibrations or othersettings utilized by the lead and trailing sensors where knowledgegained by the lead sensor could be expected to provide informationutilizable for the trailing sensor.

Example and non-limiting configuration adjustments 3406 include changingof sensing parameters such as cut-off times to observe peak values forultra-sonic processing, adjustments of rationality values forultra-sonic processing, enabling of trailing sensors or additionaltrailing sensors (e.g., X-ray, gamma ray, high resolution cameraoperations, etc.), adjustment of a sensor sampling rate (e.g., faster orslower), adjustment of fault cut-off values (e.g., increase or decreasefault cutoff values), adjustment of any transducer configurableproperties (e.g., voltage, waveform, gain, filtering operations, and/orreturn detection algorithm), and/or adjustment of a sensor range orresolution value (e.g., increase a range in response to a lead sensingvalue being saturated or near a range limit, decrease a range inresponse to a lead sensing value being within a specified range window,and/or increase or decrease a resolution of the trailing sensor). Incertain embodiments, a configuration adjustment 3406 to adjust asampling rate of a trailing sensor includes by changing a movement speedof an inspection robot. Example and non-limiting configurationadjustments include any parameters described in relation to FIGS. 39,40, and 43-48 and the related descriptions. It can be seen that theknowledge gained from the lead inspection data 3402 can be utilized toadjust the trailing sensor plan which can result more reliable data(e.g., where calibration assumptions appear to be off-nominal for thereal inspection surface), the saving of one or more inspection runs(e.g., reconfiguring the sensing plan in real-time to complete asuccessful sensing run during inspection operations), improvedoperations for a subsequent portion of a sensing run (e.g., a firstinspection run of the inspection surface improves the remaininginspection runs, even if the vertical track of the first inspection runmust be repeated), and/or efficient utilization of expensive sensingoperations by utilizing such operations only when the lead inspectiondata 3402 indicates such operations are useful or required. The examplecontroller 802 includes a sensor operation circuit 3408 that adjustsparameters of the trailing sensor in response to the configurationadjustment 3406, and the inspection data circuit 804 interpretingtrailing inspection data 3410, wherein the trailing sensors areresponsive to the adjusted parameters by the sensor operation circuit.

Referencing FIG. 35, an example procedure 3500 to configure a trailingsensor in response to a leading sensor value is depicted. The exampleprocedure 3500 includes an operation 3502 to interpret lead inspectiondata provided by a leading sensor, and an operation 3504 to determinewhether the lead inspection data indicates that a trailing sensorconfiguration should be adjusted. Where the operation 3504 determinesthat the trailing sensor configuration should be adjusted, the exampleprocedure 3500 includes an operation 3506 to adjust the trailing sensorconfiguration in response to the lead inspection data. Example andnon-limiting operations 3506 to adjust a trailing sensor configurationinclude changing a calibration for the sensor (e.g., an analog/digitalprocessor configuration, cutoff time values, and/or speed-of-soundvalues for one or more materials), changing a range or resolution of thetrailing sensor, enabling or disabling sensing operations of a trailingsensor, and/or adjusting a speed of travel of an inspection robot. Incertain embodiments, operations 3506 include adjusting a horizontalposition of a trailing sensor (e.g., where a horizontal position of asled 1 on a payload 2 is actively controllable by a controller 802,and/or adjusted manually between the lead sensing operation and thetrailing sensing operation).

In certain embodiments, lead inspection data 3402 includes ultra-sonicinformation such as processed ultra-sonic information from a sensor, andthe sensor configuration circuit 3404 determines to utilize aconsumable, slower, and/or more expensive sensing, repair, and/ormarking operation by providing a configuration adjustment 3406instructing a trailing sensor to operate, or to change nominaloperations, in response to the lead inspection data 3402. For example,lead inspection data 3402 may indicate a thin wall, and sensorconfiguration circuit 3404 provides the configuration adjustment 3406 toalter a trailing operation such as additional sensing with a morecapable sensor (e.g., a more expensive or capable ultra-sonic sensor, anX-ray sensor, a gamma ray sensor, or the like) and/or to operate arepair or marking tool (e.g., which may have a limited or consumableamount of coating material, marking material, or the like) at thelocation determined to have the thin wall. Accordingly, expense, time,and/or operational complication can be added to inspection operations ina controlled manner according to the lead inspection data 3402.

An example apparatus is disclosed to perform an inspection of anindustrial surface. Many industrial surfaces are provided in hazardouslocations, including without limitation where heavy or dangerousmechanical equipment operates, in the presence of high temperatureenvironments, in the presence of vertical hazards, in the presence ofcorrosive chemicals, in the presence of high pressure vessels or lines,in the presence of high voltage electrical conduits, equipment connectedto and/or positioned in the vicinity of an electrical power connection,in the presence of high noise, in the presence of confined spaces,and/or with any other personnel risk feature present. Accordingly,inspection operations often include a shutdown of related equipment,and/or specific procedures to mitigate fall hazards, confined spaceoperations, lockout-tagout procedures, or the like. In certainembodiments, the utilization of an inspection robot allows for aninspection without a shutdown of the related equipment. In certainembodiments, the utilization of an inspection robot allows for ashutdown with a reduced number of related procedures that would berequired if personnel were to perform the inspection. In certainembodiments, the utilization of an inspection robot provides for apartial shutdown to mitigate some factors that may affect the inspectionoperations and/or put the inspection robot at risk, but allows for otheroperations to continue. For example, it may be acceptable to positionthe inspection robot in the presence of high pressure or high voltagecomponents, but operations that generate high temperatures may be shutdown.

In certain embodiments, the utilization of an inspection robot providesadditional capabilities for operation. For example, an inspection robothaving positional sensing within an industrial environment can requestshutdown of only certain aspects of the industrial system that arerelated to the current position of the inspection robot, allowing forpartial operations as the inspection is performed. In another example,the inspection robot may have sensing capability, such as temperaturesensing, where the inspection robot can opportunistically inspectaspects of the industrial system that are available for inspection,while avoiding other aspects or coming back to inspect those aspectswhen operational conditions allow for the inspection. Additionally, incertain embodiments, it is acceptable to risk the industrial robot(e.g., where shutting down operations exceed the cost of the loss of theindustrial robot) to perform an inspection that has a likelihood ofsuccess, where such risks would not be acceptable for personnel. Incertain embodiments, a partial shutdown of a system has lower cost thana full shutdown, and/or can allow the system to be kept in a conditionwhere restart time, startup operations, etc. are at a lower cost orreduced time relative to a full shutdown. In certain embodiments, theenhanced cost, time, and risk of performing additional operations beyondmere shutdown, such as compliance with procedures that would be requiredif personnel were to perform the inspection, can be significant.

Referencing FIG. 36, an example apparatus 3600 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted schematically. The example apparatus 3600includes a position definition circuit 3602 that interprets positioninformation 3604, and/or determines a plant position definition 3606(e.g., a plant definition value) and an inspection robot position (e.g.,as one or more plant position values 3614) in response to the positioninformation 3604. Example and non-limiting position information 3604includes relative and/or absolute position information—for example adistance from a reference position (e.g., a starting point, stoppingpoint, known object in proximity to the plant, industrial system, and/orinspection surface, or the like). In certain embodiments, positioninformation 3604 is determinable according to a global positioningservice (GPS) device, ultra-wide band radio frequency (RF) signaling,LIDAR or other direct distance measurement devices (includingline-of-sight and/or sonar devices), aggregating from reference points(e.g., routers, transmitters, know devices in communication with theinspection robot, or the like), utilizing known obstacles as a referencepoint, encoders (e.g., a wheel counter or other device), barometricsensors (e.g., altitude determination), utilization of a known sensedvalue correlated to position (e.g., sound volume or frequency,temperature, vibration, etc.), and/or utilizing an inertial measurementunit (e.g., measuring and/or calculating utilizing an accelerometerand/or gyroscope). In certain embodiments, values may be combined todetermine the position information 3604—for example in 3-D space withoutfurther information, four distance measurements are ordinarily requiredto determine a specific position value. However, utilizing otherinformation, such as a region of the inspection surface that theinspection robot is operating on (e.g., which pipe the inspection robotis climbing), an overlay of the industrial surface over the measurementspace, a distance traveled from a reference point, a distance to areference point, etc., the number of distance measurements required todetermine a position value can be reduced to three, two, one, or eveneliminated and still position information 3604 is determinable. Incertain embodiments, the position definition circuit 3602 determines theposition information 3604 completely or partially on dead reckoning(e.g., accumulating speed and direction from a known position, and/ordirection combined with a distance counter), and/or corrects theposition information 3604 when feedback based position data (e.g., atrue detected position) is available.

Example and non-limiting plant position values 3608 include the robotposition information 3604 integrated within a definition of the plantspace, such as the inspection surface, a defined map of a portion of theplant or industrial system, and/or the plant position definition 3606.In certain embodiments, the plant space is predetermined, for example asa map interpreted by the controller 802 and/or pre-loaded in a data filedescribing the space of the plant, inspection surface, and/or a portionof the plant or industrial surface. In certain embodiments, the plantposition definition 3606 is created in real-time by the positiondefinition circuit 3602—for example by integrating the positioninformation 3604 traversed by the inspection robot, and/or by creating avirtual space that includes the position information 3604 traversed bythe inspection robot. For example, the position definition circuit 3602may map out the position information 3604 over time, and create theplant position definition 3606 as the aggregate of the positioninformation 3604, and/or create a virtual surface encompassing theaggregated plant position values 3614 onto the surface. In certainembodiments, the position definition circuit 3602 accepts a plant shapevalue 3608 as an input (e.g., a cylindrical tank being inspected by theinspection robot having known dimensions), deduces the plant shape value3608 from the aggregated position information 3604 (e.g., selecting fromone of a number of simple or available shapes that are consistent withthe aggregated plant position definition 3606), and/or prompts a user(e.g., an inspection operator and/or a client for the data) to selectone of a number of available shapes to determine the plant positiondefinition 3606.

The example apparatus 3600 includes a data positioning circuit 3610 thatinterprets inspection data 3612 and correlates the inspection data 3612to the position information 3604 and/or to the plant position values3614. Example and non-limiting inspection data 3612 includes: senseddata by an inspection robot; environmental parameters such as ambienttemperature, pressure, time-of-day, availability and/or strength ofwireless communications, humidity, etc.; image data, sound data, and/orvideo data taken during inspection operations; metadata such as aninspection number, customer number, operator name, etc.; setupparameters such as the spacing and positioning of sleds, payloads,mounting configuration of sensors, and the like; calibration values forsensors and sensor processing; and/or operational parameters such asfluid flow rates, voltages, pivot positions for the payload and/orsleds, inspection robot speed values, downforce parameters, etc. Incertain embodiments, the data positioning circuit 3610 determines thepositional information 3604 corresponding to inspection data 3612values, and includes the positional information 3604 as an additionalparameter with the inspection data 3612 values and/or stores acorrespondence table or other data structure to relate the positionalinformation 3604 to the inspection data values 3612. In certainembodiments, the data positioning circuit 3610 additionally oralternatively determines the plant position definition 3606, andincludes a plant position value 3614 (e.g., as a position within theplant as defined by the plant position definition 3606) as an additionalparameter with the inspection data 3612 values and/or stores acorrespondence table or other data structure to relate the plantposition values 3614 to the inspection data values 3612. In certainembodiments, the data positioning circuit 3610 creates position informeddata 3616, including one or more, or all, aspects of the inspection data3612 correlated to the position information 3604 and/or to the plantposition values 3614.

In certain embodiments, for example where dead reckoning operations areutilized to provide position information 3604 over a period of time, andthen a corrected position is available through a feedback positionmeasurement, the data positioning circuit 3602 updates the positioninformed inspection data 3616—for example re-scaling the data accordingto the estimated position for values according to the changed feedbackposition (e.g., where the feedback position measurement indicates theinspection robot traveled 25% further than expected by dead reckoning,position information 3604 during the dead reckoning period can beextended by 25%) and/or according to rationalization determinations orexternally available data (e.g., where over 60 seconds the inspectionrobot traverses 16% less distance than expected, but sensor readings orother information indicate the inspection robot may have been stuck for10 seconds, then the position information 3604 may be corrected torepresent the 10-seconds of non-motion rather than a full re-scale ofthe position informed inspection data 3616). In certain embodiments,dead reckoning operations may be corrected based on feedbackmeasurements as available, and/or in response to the feedbackmeasurement indicating that the dead reckoning position informationexceeds a threshold error value (e.g., 1%, 0.1%, 0.01%, etc.).

It can be seen that the operations of apparatus 3600 provide forposition-based inspection information. Certain systems, apparatuses, andprocedures throughout the present disclosure utilize and/or can benefitfrom position informed inspection data 3616, and all such embodimentsare contemplated herein. Without limitation to any other disclosuresherein, certain aspects of the present disclosure include: providing avisualization of inspection data 3612 in position information 3604 spaceand/or in plant position value 3614 space; utilizing the positioninformed inspection data 3616 in planning for a future inspection on thesame or a similar plant, industrial system, and/or inspection surface(e.g., configuring sled number and spacing, inspection robot speed,inspection robot downforce for sleds and/or sensors, sensorcalibrations, planning for traversal and/or avoidance of obstacles,etc.); providing a format for storing a virtual mark (e.g., replacing apaint or other mark with a virtual mark as a parameter in the inspectiondata 3612 correlated to a position); determining a change in a plantcondition in response to the position informed inspection data 3616(e.g., providing an indication that expected position information 3604did not occur in accordance with the plant position definition 3606—forexample indicating a failure, degradation, or unexpected object in aportion of the inspected plant that is not readily visible); and/orproviding a health indicator of the inspection surface (e.g., depictingregions that are nominal, passed, need repair, will need repair, and/orhave failed). In certain embodiments, it can be seen that constructingthe position informed inspection data 3616 using position information3604 only, including dead reckoning based position information 3604,nevertheless yields many of the benefits of providing the positioninformed inspection data 3616. In certain further embodiments, theposition informed inspection data 3616 is additionally or alternativelyconstructed utilizing the plant position definition 3606, and/or theplant position values 3614.

Referencing FIG. 37, an example procedure 3700 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted. The example procedure 3700 includes anoperation 3702 to interpret position information, an operation 3704 tointerpret inspection data, and an operation 3706 correlate theinspection data to the position information. The example procedure 3700further includes an operation 3708 to correct the position information(e.g., updating a dead reckoning-based position information), and toupdate the correlation of the inspection data to the positioninformation. The example procedure further includes an operation 3710 toprovide position informed inspection data in response to the correlatedinspection data. In certain embodiments, operation 3706 is additionallyor alternatively performed on the position informed inspection data,where the position informed inspection data is corrected, and operation3710 includes providing the position informed inspection data. Incertain embodiments, one or more operations of a procedure 3700 areperformed by a controller 802.

Referencing FIG. 38, an example procedure 3800 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted. In addition to operations of procedure 3700,example procedure 3800 includes an operation 3802 to determine a plantdefinition value, and an operation 3804 to determine plant positionvalues in response to the position information and the plant positiondefinition. Operation 3706 further includes an operation to correlatethe inspection data with the position information and/or the plantposition values. In certain embodiments, one or more operations ofprocedure 3800 are performed by a controller 802.

Referencing FIG. 39, an example apparatus 3900 for processingultra-sonic sensor readings is depicted schematically. The exampleapparatus 3900 includes a controller 802 having an acoustic data circuit3902 that determines return signals from the tested surface—for examplea transducer in the sensor 2202 sends a sound wave through the couplantchamber to the inspection surface, and the raw acoustic data 3904includes primary (e.g., from the surface inspection surface), secondary(e.g., from a back wall, such as a pipe wall or tank wall) and/ortertiary (e.g., from imperfections, cracks, or defects within the wall)returns from the inspection surface.

In certain embodiments, the controller 802 includes a thicknessprocessing circuit 3906 that determines a primary mode value 3908 inresponse to the raw acoustic data 3904. The primary mode value 3908, incertain embodiments, includes a determination based upon a first returnand a second return of the raw acoustic data 3904, where a timedifference between the first return and the second return indicates athickness of the inspection surface material (e.g., a pipe). Theforegoing operations of the thickness processing circuit 3906 are wellknown in the art, and are standard operations for ultra-sonic thicknesstesting. However, the environment for the inspection robot is nottypical, and certain further improvements to operations are describedherein. An inspection robot, in certain embodiments, performs amultiplicity of ultra-sonic thickness determinations, often withsimultaneous (or nearly) operations from multiple sensors. Additionally,in certain embodiments, it is desirable that the inspection robotoperate: autonomously without the benefit of an experienced operator;without high-end processing in real-time to provide substantial displaysto a user to determine whether parameters are not being determinedproperly; and/or with limited communication resources utilized forpost-processing that is fast enough that off nominal operation can beadjusted after significant post-processing.

In certain embodiments, the thickness processing circuit 3906 determinesa primary mode score value 3910. In certain embodiments, the thicknessprocessing circuit 3906 determines the primary mode score value 3910 inresponse to a time of arrival for the primary (e.g., inspection surfaceface) return from the raw acoustic data 3904. Because the delay time forthe sensor is a known and controlled value (e.g., reference FIGS. 28 and31, and the related description), the return time of the primary returnis known with high confidence. Additionally or alternatively, thethickness processing circuit 3906 determines the primary mode scorevalue 3910 in response to the character of the primary return—forexample a sharp peak of a known width and/or amplitude. In certainembodiments, the primary mode score value 3910 calculation is calibratedin response to the material of the inspection surface—although knownmaterials such as iron, various types of steel, and other surfaces canutilize nominal calibrations. In certain embodiments, the configurationadjustment 3406 based on lead inspection data 3402 is utilized tocalibrate a primary mode score value 3910 calculation for a sensorproviding the trailing inspection data 3410. In certain embodiments,determining that the first peak (related to the primary return) meetsexpected characteristics is sufficient to provide confidence to utilizethe primary mode value 3908 as the ultra-sonic thickness value 3912. Incertain embodiments, the ultra-sonic thickness value 3912 is theinspection data for the sensor, and/or a part of the inspection data forthe sensor.

In certain embodiments, the thickness processing circuit 3906additionally or alternatively considers the timing of arrival for asecondary return, peak arrival time, and/or peak width of the secondaryreturn (e.g., from the back wall) in determining the primary mode scorevalue 3910. For example, if the secondary return indicates a wallthickness that is far outside of an expected thickness value, eithergreater or lower, the primary mode score value 3910 may be reduced. Incertain embodiments, if the secondary return has a peak characteristicthat is distinct from the expected characteristic (e.g., too narrow, notsharp, etc.) then the primary mode score value 3910 may be reduced.Additionally or alternatively, feedback data regarding the sensor may beutilized to adjust the primary mode score value 3910—for example if thesensor is out of alignment with the inspection surface, the sensor (orsled) has lifted off of the inspection surface, a sled position for asled having an acoustic sensor, and/or if a couplant anomaly isindicated (e.g., couplant flow is lost, a bubble is detected, etc.) thenthe primary mode score value 3910 may be reduced.

In certain embodiments, for example when the primary mode score value3910 indicates that the primary mode value 3908 is to be trusted, thecontroller 802 includes a sensor reporting circuit 3914 that providesthe ultra-sonic thickness value 3912 in response to the primary modevalue 3908. In certain embodiments, if the primary mode score value 3910is sufficiently high, the thickness processing circuit 3906 omitsoperations to determine a secondary mode value 3916. In certainembodiments, the thickness processing circuit 3906 performs operationsto determine the secondary mode value 3916 in response to the primarymode score value 3910 is at an intermediate value, and/or if feedbackdata regarding the sensor indicates off-nominal operation, even when theprimary mode score value 3910 is sufficiently high (e.g., to allow forimproved post-processing of the inspection data). In certainembodiments, the thickness processing circuit 3906 determines thesecondary mode value 3916 at all times, for example to allow forimproved post-processing of the inspection data. In certain embodiments,the sensor reporting circuit 3914 provides processed values for theprimary mode value 3908 and/or the secondary mode value 3916, and/or theprimary mode scoring value 3910 and/or a secondary mode score value3918, either as the inspection data and/or as stored data to enablepost-processing and/or future calibration improvements. In certainembodiments, the sensor reporting circuit 3914 provides the raw acousticdata 3904, either as the inspection data and/or as stored data to enablepost-processing and/or future calibration improvements.

The example thickness processing circuit 3906 further determines, incertain embodiments, a secondary mode value 3916. An example secondarymode value 3916 includes values determined from a number of reflectedpeaks—for example determining which of a number of reflected peaks areprimary returns (e.g., from a face of the inspection surface) and whichof a number of reflected peaks are secondary returns (e.g., from a backwall of the inspection surface). In certain embodiments, a Fast-FourierTransform (FFT), wavelet analysis, or other frequency analysis techniqueis utilized by the thickness processing circuit 3906 to determine theenergy and character of the number of reflected peaks. In certainembodiments, the thickness processing circuit 3906 determines asecondary mode score value 3918—for example from the character andconsistency of the peaks, and determines an ultra-sonic thickness value3912 from the peak-to-peak distance of the number of reflected peaks.The operations of the example apparatus 3900, which in certainembodiments favor utilization of the primary mode value 3908, providefor rapid and high confidence determinations of the ultra-sonicthickness value 3912 in an environment where a multiplicity of sensorsare providing raw acoustic data 3904, computing resources are limited,and a large number of sensor readings are to be performed withoutsupervision of an experienced operator.

In certain embodiments, any one or more of the ultra-sonic thicknessvalue 3912, the primary mode value 3908, the secondary mode value 3916,the primary mode score value 3910, and/or the secondary mode score value3918 are provided or stored as position informed inspection data 3616.The correlation of the values 3912, 3908, 3916, 3910, and/or 3918 withposition data as position informed inspection data 3616 provides forrapid visualizations of the characteristics of the inspection surface,and provides for rapid convergence of calibration values for inspectionoperations on the inspection surface and similar surfaces. In certainembodiments, the raw acoustic data 3904 is provided or stored asposition informed inspection data 3616.

Referencing FIG. 40, an example procedure 4000 to process ultra-sonicsensor readings is depicted schematically. In certain embodiments,procedure 4000 processes ultra-sonic sensor readings for an inspectionrobot having a number of ultra-sonic sensor mounted thereon. The exampleprocedure 4000 includes an operation 4002 to interrogate an inspectionsurface with an acoustic signal (e.g., acoustic impulse from atransducer). The example procedure 4000 further includes an operation4004 to determine raw acoustic data, such as return signals from theinspection surface. The example procedure 4000 further includes anoperation 4006 to determine a primary mode score value in response to aprimary peak value, and/or further in response to a secondary peakvalue, from the raw acoustic data. The example procedure 4000 furtherincludes an operation 4008 to determine whether the primary mode scorevalue exceeds a high threshold value, such as whether the primary modevalue is deemed to be reliable without preserving a secondary modevalue. In response to the operation 4008 determining the primary modescore value exceeds the high threshold value, the procedure 4000 furtherincludes an operation 4010 to determine the primary mode value, and anoperation 4012 to report the primary mode value as an ultra-sonicthickness value. In response to the operation 4008 determining theprimary mode score value does not exceed the high threshold value, theprocedure includes an operation 4014 to determine whether the primarymode score value exceeds a primary mode utilization value. In certainembodiments, in response to the operation 4014 determining the primarymode score value exceeds the primary mode utilization value, theprocedure 4000 includes the operation 4010 to determine the primary modevalue, an operation 4011 to determine the secondary mode value, and theoperation 4012 to provide the primary mode value as the ultra-sonicthickness value. In response to the operation 4014 determining theprimary mode score value does not exceed the primary mode utilizationvalue, the procedure 4000 includes the operation 4018 to determine thesecondary mode value and an operation 4022 to determine the secondarymode score value. The procedure 4000 further includes an operation 4024to determine whether the secondary mode score value exceeds a secondarymode utilization value, and in response to operation 4024 determiningthe secondary mode score value exceeds the secondary mode utilizationvalue, the procedure 4000 includes an operation 4026 to provide thesecondary mode value as the ultra-sonic thickness value. In response tothe operation 4024 determining the secondary mode score value does notexceed the secondary mode utilization value, the procedure 4000 includesan operation 4028 to provide an alternate output as the ultra-sonicthickness value. In certain embodiments, operation 4028 includesproviding an error value (e.g., data not read), one of the primary modevalue and the secondary mode value having a higher score, and/orcombinations of these (e.g., providing a “best” value, along with anindication that the ultra-sonic thickness value for that reading may notbe reliable).

As with all schematic flow diagrams and operational descriptionsthroughout the present disclosure, operations of procedure 4000 may becombined or divided, in whole or part, and/or certain operations may beomitted or added. Without limiting the present description, it is notedthat operation 4022 to determine the secondary mode score value andoperation 4024 to determine whether the secondary mode score valueexceeds a utilization threshold may operate together such that operation4018 to determine the secondary mode score is omitted. For example,where the secondary mode score value indicates that the secondary modevalue is not sufficiently reliable to use as the ultra-sonic thicknessvalue, in certain embodiments, processing to determine the secondarymode value are omitted. In certain embodiments, one or more ofoperations 4014 and/or 4008 to compare the primary mode score value tocertain thresholds may additionally or alternatively include comparisonof the primary mode score value to the secondary mode score value,and/or utilization of the secondary mode value instead of the primarymode value where the secondary mode score value is higher, orsufficiently higher, than the primary mode score value. In certainembodiments, both the primary mode value and the secondary mode valueare determined and stored or communicated, for example to enhance futurecalibrations and/or processing operations, and/or to enablepost-processing operations. In certain embodiments, one or moreoperations of procedure 4200 are performed by a controller 802.

Referencing FIG. 43, an example apparatus 4300 for operating a magneticinduction sensor for an inspection robot is depicted. In certainembodiments, the magnetic induction sensor is mounted on a sled 1,and/or on a payload 2. In certain embodiments, the magnetic inductionsensor is a lead sensor as described throughout the present disclosure,although operations of the apparatus 4300 for operating the magneticinduction sensor for the inspection robot include the magnetic inductionsensor positioned on any payload and/or any logistical inspectionoperation runs. In certain embodiments, the magnetic induction sensor isa lead sensor and positioned on a same sled as an ultra-sonic or othersensor. In certain embodiments, the magnetic induction sensor isincluded on a payload 2 with other sensors, potentially including anultra-sonic sensor, and may be on a same sled 1 or an offset sled (e.g.,one or more magnetic sensors on certain sleds 1 of a payload 2, andultra-sonic or other sensors on other sleds 1 of the payload 2).

An example apparatus 4300 includes an EM data circuit 4302 structured tointerpret EM induction data 4304 provided by a magnetic inductionsensor. The EM induction data 4304 provides an indication of thethickness of material, including coatings, debris, non-ferrous metalspray material (e.g., repair material), and/or damage, between thesensor and a substrate ferrous material, such as a pipe, tube, wall,tank wall, or other material provided as a substrate for an inspectionsurface. The foregoing operations of the EM data circuit 4302 andmagnetic induction sensor are well known in the art, and are standardoperations for determining automotive paint thickness or otherapplications. However, the environment for the inspection robot is nottypical, and certain further improvements to operations are describedherein.

In certain embodiments, an inspection robot includes sledconfigurations, including any configurations described throughout thepresent disclosure, to ensure expected contact, including proximityand/or orientation, between the inspection surface and the magneticinduction sensor. Accordingly, a magnetic induction sensor included on asled 1 of the inspection robot in accordance with the present disclosureprovides a reliable reading of distance to the substrate ferrousmaterial. In certain embodiments, the apparatus 4300 includes asubstrate distance circuit 4306 that determines a substrate distancevalue 4308 between the magnetic induction sensor and a ferrous substrateof the inspection surface. Additionally or alternatively, the substratedistance value 4308 may be a coating thickness, a delay line correctionfactor (e.g., utilized by a thickness processing circuit 3906), a totaldebris-coating distance, or other value determined in response to thesubstrate distance value 4308.

In certain embodiments, the controller 802 further includes an EMdiagnostic circuit 4310 that supports one or more diagnostics inresponse to the substrate distance value 4308. An example diagnosticincludes a diagnostic value 4312 (e.g., a rationality diagnostic value,or another value used for a diagnostic check), wherein the EM diagnosticcircuit 4310 provides information utilized by the thickness processingcircuit 3906, for example to a thickness processing circuit 3906. Forexample, the layer of coating, debris, or other material between thesubstrate of the inspection surface and an ultra-sonic sensor can affectthe peak arrival times. In a further example, the layer of coating,debris, or other material between the substrate of the inspectionsurface and an ultra-sonic sensor can act to increase the effectivedelay line between the transducer of the ultra-sonic sensor and theinspection surface. In certain embodiments, the thickness processingcircuit 3906 utilizes the rationality diagnostic value 4312 to adjustexpected arrival times for the primary return and/or secondary returnvalues, and/or to adjust a primary mode scoring value and/or a secondarymode score value.

In certain embodiments, the EM diagnostic circuit 4310 operates todetermine a sensor position value 4314. In certain embodiments, thesensor position value 4314 provides a determination of the sensordistance to the substrate. In certain embodiments, the sensor positionvalue 4314 provides a rationality check whether the sensor is positionedin proximity to the inspection surface. For example, an excursion of theEM induction data 4304 and/or substrate distance value 4308 may beunderstood to be a loss of contact of the sensor with the inspectionsurface, and/or may form a part of a determination, combined with otherinformation such as an arm 20, sled 1, or payload 2 position value, avalue of any of the pivots 16, 17, 18, and/or information from a cameraor other visual indicator, to determine that a sled 1 including themagnetic induction sensor, and/or the magnetic induction sensor, is notproperly positioned with regard to the inspection surface. Additionallyor alternatively, a thickness processing circuit 3906 may utilize thesensor position value 4314 to adjust the primary mode scoring valueand/or the secondary mode score value—for example to exclude or labeldata that is potentially invalid. In certain embodiments, the sensorposition value 4314 is utilized on a payload 2 having both anultra-sonic sensor and a magnetic induction sensor, and/or on a sled 1having both an ultra-sonic sensor and a magnetic induction sensor (e.g.,where the sensor position value 4314 is likely to provide directinformation about the ultra-sonic sensor value). In certain embodiments,the sensor position value 4314 is utilized when the magnetic inductionsensor is not on a same payload 2 or sled 1 with an ultra-sonicsensor—for example by correlating with position data to identify apotential obstacle or other feature on the inspection surface that maymove the sled 1 out of a desired alignment with the inspection surface.In certain embodiments, the sensor position value 4314 is utilized whenthe magnetic induction sensor is not on a same payload 2 or sled 1 withan ultra-sonic sensor, and is combined with other data in a heuristiccheck to determine if the ultra-sonic sensor (and/or related sled orpayload) experiences the same disturbance at the same location that themagnetic induction sensor (and/or related sled or payload) experienced.

In certain embodiments, the substrate distance value 4308 is provided toa thickness processing circuit 3906, which utilizes the substratedistance value 4308 to differentiate between a utilization of theprimary mode value 3908 and/or the secondary mode value 3916. Forexample, the thickness of a coating on the inspection surface can affectreturn times and expected peak times. Additionally or alternatively,where the speed of sound through the coating is known or estimated, thepeak analysis of the primary mode value 3908 and/or the secondary modevalue 3916 can be adjusted accordingly. For example, the secondary modevalue 3916 will demonstrate additional peaks, which can be resolved witha knowledge of the coating thickness and material, and/or the speed ofsound of the coating material can be resolved through deconvolution andfrequency analysis of the returning peaks if the thickness of thecoating is known. In another example, the primary mode value 3908 can beadjusted to determine a true substrate first peak response (which will,in certain embodiments, occur after a return from the coating surface),which can be resolved with a knowledge of the coating thickness and/orthe speed of sound of the coating material. In certain embodiments, alikely composition of the coating material is known—for example basedupon prior repair operations performed on the inspection surface. Incertain embodiments, as described, sound characteristics of the coatingmaterial, and/or effective sound characteristics of a pseudo-material(e.g., a mix of more than one material modeled as an aggregatedpseudo-material) acting as the aggregate of the coating, debris, orother matter on the substrate of the inspection surface, can bedetermined through an analysis of the ultra-sonic data and/or coupledwith knowledge of the thickness of the matter on the substrate of theinspection surface.

Referencing FIG. 44, an example procedure 4400 for operating andanalyzing a magnetic induction sensor on an inspection robot isschematically depicted. The example procedure 4400 includes an operation4402 to interpret EM induction data provided by a magnetic inductionsensor, and an operation 4404 to determine a substrate distance valuebetween the magnetic induction sensor and a ferrous substrate of theinspection surface. The example procedure 4400 further includes anoperation 4406 to determine a sensor position value, such as: a sensordistance from a substrate of the inspection surface; and/or a sensorpass/fail orientation, alignment or position check. In certainembodiments, the example procedure 4400 further includes an operation4408 to adjust a primary mode scoring value and/or a secondary modescore value in response to the substrate distance value and/or thesensor position value. In certain embodiments, operation 4408 includesan operation to set the primary mode scoring value and/or secondary modescore value to a value that excludes the primary mode value and/or thesecondary mode value from being used, and/or labels the primary modevalue and/or the secondary mode value as potentially erroneous. Incertain embodiments, operation 4410 determines a reliability of theprimary mode value and/or the secondary mode value—for example wheresonic properties of the matter between the ultra-sonic sensor and theinspection surface substrate are determined with a high degree ofreliability—and the reliability determined from operation 4410 for theprimary mode value and/or the secondary mode value is utilized to adjustthe primary mode scoring value and/or the secondary mode score value. Anexample procedure 4400 further includes an operation 4410 to adjust apeak analysis of a primary mode value and/or a secondary mode value inresponse to the substrate distance value and/or the sensor positionvalue. In certain embodiments, one or more operations of procedure 4400are performed by a controller 802.

Referencing FIG. 45, an example procedure 4410 to adjust a peak analysisof a primary mode value and/or a secondary mode value is schematicallydepicted. The example procedure 4410 includes an operation 4504 toresolve a thickness and a sound characteristic of material positionedbetween a substrate of an inspection surface and an ultra-sonic sensor.In certain embodiments, operation 4504 includes a deconvolution of peakvalues including a frequency analysis of peaks observed in view of thesubstrate distance value and/or the sensor position value. In certainembodiments, the example procedure 4410 further includes an operation4502 to determine a likely composition of the coating material—forexample in response to a defined parameter by an inspection operator,and/or a previously executed repair operation on the inspection surface.In certain embodiments, operations of any of procedure 4400 and/orprocedure 4410 are performed in view of position information of themagnetic induction sensor, and/or correlating position information ofthe ultra-sonic sensor. In certain embodiments, one or more operationsof procedure 4410 are performed by a controller 802.

Referencing FIG. 46, an example procedure 4600 to adjust an inspectionoperation in real-time in response to a magnetic induction sensor isschematically depicted. In certain embodiments, example procedure 4600includes an operation 4602 to determine an induction processingparameter, such as a substrate distance value, a sensor position value,and/or a rationality diagnostic value. In certain embodiments, theexample procedure 4600 includes an operation 4604 to adjust aninspection plan in response to the induction processing parameter.Example and non-limiting operations 4604 to an inspection plan include:adjusting a sensor calibration value (e.g., for an ultra-sonic sensor, atemperature sensor, etc.) for a sensor that may be affected by thecoating, debris, or other matter between the magnetic induction sensorand a substrate of the inspection surface; adjusting an inspectionresolution for one or more sensors for a planned inspection operation;adjusting a planned inspection map display for an inspection operation,and/or including adjusting sensors, sled positions, and/or an inspectionrobot trajectory to support the planned inspection map display;adjusting an inspection robot trajectory (e.g., locations, paths, numberof runs, and/or movement speed on the inspection surface); adjusting anumber, type, and/or positioning (e.g., sled numbers, placement, and/orpayload positions) for sensors for an inspection operation; adjusting awheel magnet strength and/or wheel configuration of an inspection robotin response to the induction processing parameter (e.g., adjusting foran expected distance to a ferrous material, configuring the wheels tomanage debris, etc.); adjusting a sled ramp configuration (e.g., sledramp leading and/or following slope, shape, and/or depth); and/oradjusting a down force for a sled and/or sensor. Operations 4604 may beperformed in real-time, such as a change of an inspection plan duringinspection operations, and/or at design or set-up time, such as a changeof a configuration for the inspection robot or any other aspectsdescribed herein before an inspection run, between inspection runs, orthe like.

In certain embodiments, the example procedure 4600 includes an operation4606 to perform an additional inspection operation in response to theinduction processing parameter. For example, operation 4606 may includeoperations such as: inspecting additional portions of the inspectionsurface and/or increasing the size of the inspection surface (e.g., toinspect other portions of an industrial system, facility, and/orinspection area encompassing the inspection surface); to activatetrailing payloads and/or a rear payload to perform the additionalinspection operation; re-running an inspection operation over aninspection area that at least partially overlaps a previously inspectedarea; and/or performing a virtual additional inspection operation—forexample re-processing one or more aspects of inspection data in view ofthe induction processing parameter.

In certain embodiments, the example procedure 4600 includes an operation4608 to follow a detected feature, for example activating a sensorconfigured to detect the feature as the inspection robot traverses theinspection surface, and/or configuring the inspection robot to adjust atrajectory to follow the feature (e.g., by changing the robot trajectoryin real-time, and/or performing additional inspection operations tocover the area of the feature). Example and non-limiting featuresinclude welds, grooves, cracks, coating difference areas (e.g., thickercoating, thinner coating, and/or a presence or lack of a coating). Incertain embodiments, the example procedure 4600 includes an operation4610 to perform at least one of a marking, repair, and/or treatmentoperation, for example marking features (e.g., welds, grooves, cracks,and/or coating difference areas), and/or performing a repair and/ortreatment operation (e.g., welding, applying an epoxy, applying acleaning operation, and/or applying a coating) appropriate for afeature. In certain embodiments, operation 4610 to perform a markingoperation includes marking the inspection surface in virtual space—forexample as a parameter visible on an inspection map but not physicallyapplied to the inspection surface.

In certain embodiments, the example procedure 4600 includes an operation4612 to perform a re-processing operation in response to the inductionprocessing parameter. For example, and without limitation, acoustic rawdata, primary mode values and/or primary mode score values, and/orsecondary mode values and/or secondary mode score values may berecalculated over at least a portion of an inspection area in responseto the induction processing parameter. In certain embodiments,ultra-sonic sensor calibrations may be adjusted in a post-processingoperation to evaluate, for example, wall thickness and/or imperfections(e.g., cracks, deformations, grooves, etc.) utilizing the inductionprocessing parameter(s).

Operations for procedure 4600 are described in view of an inductionprocessing parameter for clarity of description. It is understood that aplurality of induction processing parameters, including multipleparameter types (e.g., coating presence and/or coating thickness) aswell as a multiplicity of parameter determinations (e.g., position basedinduction processed values across at least a portion of the inspectionsurface) are likewise contemplated herein. In certain embodiments, oneor more operations of procedure 4600 are performed by a controller 802.

Referencing FIG. 47, an example apparatus 4700 for utilizing a profilingsensor on an inspection robot is schematically depicted. Example andnon-limiting profiling sensors include a laser profiler (e.g., a highspatial resolution laser beam profiler) and/or a high resolution caliperlog. A profiling sensor provides for a spatial description of theinspection surface—for example variations in a pipe 502 or other surfacecan be detected, and/or a high resolution contour of at least a portionof the inspection surface can be determined. In certain embodiments, acontroller 802 includes a profiler data circuit 4702 that interpretsprofiler data 4704 provided by the profiling sensor. The examplecontroller 802 further includes an inspection surface characterizationcircuit 4706 that provides a characterization of the shape of theinspection surface in response to the profiler data—for example as ashape description 4708 of the inspection surface, including anomalies,variations in the inspection surface geometry, and/or angles of theinspection surface (e.g., to determine a perpendicular angle to theinspection surface). The example controller 802 further includes aprofile adjustment circuit 4710 that provides an inspection operationadjustment 4712 in response to the shape description 4708. Example andnon-limiting inspection operation adjustments 4712 include: providing anadjustment to a sled, payload, and/or sensor orientation within a sled(e.g., to provide for a more true orientation due to a surface anomaly,including at least changing a number and configuration of sleds on apayload, configuring a payload to avoid an obstacle, adjusting a downforce of a sled, arm, sensor, and/or payload, and/or adjusting a shapeof a sled bottom surface); a change to a sensor resolution value (e.g.,to gather additional data in the vicinity of an anomaly or shapedifference of the inspection surface); a post-processing operation(e.g., re-calculating ultra-sonic and/or magnetic induction data—forexample in response to a shape of the inspection surface, and/or inresponse to a real orientation of a sensor to the inspectionsurface—such as correcting for oblique angles and subsequent sonicand/or magnetic effects); a marking operation (e.g., marking an anomaly,shape difference, and/or detected obstacle in real space—such as on theinspection surface—and/or in virtual space such as on an inspectionmap); and/or providing the inspection operation adjustment 4712 as aninstruction to a camera to capture an image of an anomaly and/or a shapedifference.

Referencing FIG. 48, an example procedure 4800 for utilizing a profilingsensor on an inspection robot is schematically depicted. The exampleprocedure 4800 includes an operation 4802 to operate a profiling sensoron at least a portion of an inspection surface, and an operation 4804 tointerpret profiler data in response to the operation 4802. The exampleprocedure 4800 further includes an operation 4806 to characterize ashape of the inspection surface, and/or thereby provide a shapedescription for the inspection surface, and an operation 4808 to adjustan inspection operation in response to the shape of the inspectionsurface.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is pivotally mounted to one of the plurality ofarms; and a plurality of sensors, wherein each sensor is mounted to acorresponding one of the sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds is contoured in response to a shape ofthe inspection surface.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

An example system may further include wherein each of the plurality ofarms is further pivotally mounted to the one of the plurality ofpayloads with two degrees of rotational freedom.

An example system may further include wherein the sleds as mounted onthe arms include three degrees of rotational freedom.

An example system may further include a biasing member coupled to eachone of the plurality of arms, and wherein the biasing member provides abiasing force to corresponding one of the plurality of sleds, whereinthe biasing force is directed toward the inspection surface.

An example system may further include wherein each of the plurality ofpayloads has a plurality of the plurality of arms mounted thereon.

An example system includes an inspection robot, and a plurality of sledsmounted to the inspection robot; a plurality of sensors, wherein eachsensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds; and acouplant chamber disposed within each of the plurality of sleds, eachcouplant chamber interposed between a transducer of the sensor mountedto the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include a couplant entry for the couplantchamber, wherein the couplant entry is positioned between the cone tipportion and the sensor mounting end.

An example system may further include wherein the couplant entry ispositioned at a vertically upper side of the cone when the inspectionrobot is positioned on the inspection surface.

An example system may further include wherein the couplant exit openingincludes one of flush with the bottom surface and extending through thebottom surface.

An example system includes an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is mounted to one of the plurality of arms; aplurality of sensors, wherein each sensor is mounted to a correspondingone of the sleds such that the sensor is operationally couplable to aninspection surface in contact with a bottom surface of the correspondingone of the sleds; a couplant chamber disposed within each of theplurality of sleds, each couplant chamber interposed between atransducer of the sensor mounted to the sled and the inspection surface;and a biasing member coupled to each one of the plurality of arms, andwherein the biasing member provides a biasing force to corresponding oneof the plurality of sleds, wherein the biasing force is directed towardthe inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include a couplant entry for the couplantchamber, wherein the couplant entry is positioned between the cone tipportion and the sensor mounting end.

An example system may further include wherein the couplant entry ispositioned at a vertically upper side of the cone when the inspectionrobot is positioned on the inspection surface.

An example system may further include wherein the couplant exit openingincludes one of flush with the bottom surface and extending through thebottom surface.

An example system may further include wherein each payload includes asingle couplant connection to the inspection robot.

An example method includes providing an inspection robot having aplurality of payloads and a corresponding plurality of sleds for each ofthe payloads; mounting a sensor on each of the sleds, each sensormounted to a couplant chamber interposed between the sensor and aninspection surface, and each couplant chamber including a couplant entryfor the couplant chamber; changing one of the plurality of payloads to adistinct payload; and wherein the changing of the plurality of payloadsdoes not include disconnecting a couplant line connection at thecouplant chamber.

An example method includes providing an inspection robot having aplurality of payloads and a corresponding plurality of sleds for each ofthe payloads; mounting a sensor on each of the sleds, each sensormounted to a couplant chamber interposed between the sensor and aninspection surface, and each couplant chamber including a couplant entryfor the couplant chamber; changing one of the plurality of payloads to adistinct payload; and wherein the changing of the plurality of payloadsdoes not include dismounting any of the sensors from correspondingcouplant chambers.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled defines a chamber sized to accommodate asensor.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include a plurality of sensors, whereineach sensor is positioned in one of the chambers of a corresponding oneof the plurality of sleds.

An example system may further include wherein each chamber furtherincludes a stop, and wherein each of the plurality of sensors ispositioned against the stop.

An example system may further include wherein each sensor positionedagainst the stop has a predetermined positional relationship with abottom surface of the corresponding one of the plurality of sleds.

An example system may further include wherein each chamber furtherincludes a chamfer on at least one side of the chamber.

An example system may further include wherein each sensor extendsthrough a corresponding holding clamp, and wherein each holding clamp ismounted to the corresponding one of the plurality of sleds.

An example system may further include wherein each of the plurality ofsleds includes an installation sleeve positioned at least partiallywithin in the chamber.

An example system may further include wherein each of the plurality ofsleds includes an installation sleeve positioned at least partiallywithin in the chamber, and wherein each sensor positioned in one of thechambers engages the installation sleeve positioned in the chamber.

An example system may further include wherein each of the plurality ofsensors is positioned at least partially within an installation sleeve,and wherein each installation sleeve is positioned at least partiallywithin the chamber of the corresponding one of the plurality of sleds.

An example system may further include wherein each chamber furtherincludes wherein each of the plurality of sensors includes aninstallation tab, and wherein each of the plurality of sensorspositioned in one of the chambers engages the installation tab.

An example system may further include wherein each installation tab isformed by relief slots.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled includes a bottom surface; and aremovable layer positioned on each of the bottom surfaces.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the removable layerincludes a sacrificial film.

An example system may further include wherein the sacrificial filmincludes an adhesive backing on a side of the sacrificial film thatfaces the bottom surface.

An example system may further include wherein the removable layerincludes a hole positioned vertically below a chamber of thecorresponding one of the plurality of sleds.

An example system may further include wherein the removable layer ispositioned at least partially within a recess of the bottom surface.

An example system may further include wherein the removable layerincludes a thickness providing a selected spatial orientation between aninspection contact side of the removable layer and the bottom surface.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled includes an upper portion and areplaceable lower portion having a bottom surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the replaceable lowerportion includes a single, 3-D printable material.

An example system may further include wherein the upper portion and thereplaceable lower portion are configured to pivotally engage anddisengage.

An example system may further include wherein the bottom surface furtherincludes at least one ramp.

An example method includes interrogating an inspection surface with aninspection robot having a plurality of sleds, each sled including anupper portion and a replaceable lower portion having a bottom surface;determining that the replaceable lower portion of one of the sleds isone of damaged or worn; and in response to the determining, disengagingthe worn or damaged replaceable portion from the corresponding upperportion, and engaging a new or undamaged replaceable portion to thecorresponding upper portion.

An example method may further include wherein the disengaging includesturning the worn or damaged replaceable portion relative to thecorresponding upper portion.

An example method may further include performing a 3-D printingoperation to provide the new or undamaged replaceable portion.

An example method includes determining a surface characteristic for aninspection surface; providing a replaceable lower portion having abottom surface, the replaceable lower portion including a lower portionof a sled having an upper portion, wherein the sled includes one of aplurality of sleds for an inspection robot; and wherein the providingincludes one of performing a 3-D printing operation or selecting onefrom a multiplicity of pre-configured replaceable lower portions.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example method may further include determining the surfacecharacteristic includes determining a surface curvature of theinspection surface.

An example method may further include providing includes providing thereplaceable lower portion having at least one of a selected bottomsurface shape or at least one ramp.

An example method may further include wherein the at least one rampincludes at least one of a ramp angle and a ramp total height value.

An example system includes an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled includes a bottom surface defining aramp.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each sled further includesthe bottom surface defining two ramps, wherein the two ramps include aforward ramp and a rearward ramp.

An example system may further include wherein the ramp include at leastone of a ramp angle and a ramp total height value.

An example system may further include wherein the at least one of theramp angle and the ramp total height value are configured to traverse anobstacle on an inspection surface to be traversed by the inspectionrobot.

An example system may further include wherein the ramp includes a curvedshape.

An example system includes an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ismounted to one of the plurality of payloads; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms;and a plurality of sensors, wherein each sensor is mounted to acorresponding one of the sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each sled is pivotallymounted to one of the plurality of arms at a selected one of a pluralityof pivot point positions.

An example system may further include a controller configured to selectthe one of the plurality of pivot point positions during an inspectionrun of the inspection robot.

An example system may further include wherein the controller is furtherconfigured to select the one of the plurality of pivot point positionsin response to a travel direction of the inspection robot.

An example system may further include wherein each sled is pivotallymounted to one of the plurality of arms at a plurality of pivot pointpositions.

An example method includes providing a plurality of sleds for aninspection robot, each of the sleds mountable to a corresponding arm ofthe inspection robot at a plurality of pivot point positions;determining which of the plurality of pivot point positions is to beutilized for an inspection operation; and pivotally mounting each of thesleds to the corresponding arm at a selected one of the plurality ofpivot point positions in response to the determining.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the pivotally mounting isperformed before an inspection run by the inspection robot.

An example method may further include wherein the pivotally mounting isperformed during an inspection run by the inspection robot.

An example method may further include wherein the pivotally mounting isperformed in response to a travel direction of the inspection robot.

An example method may further include pivotally mounting each of thesleds at a selected plurality of the plurality of pivot point positionsin response to the determining.

An example method includes determining an inspection resolution for aninspection surface; configuring an inspection robot by providing aplurality of horizontally distributed sensors operationally coupled tothe inspection robot in response to the inspection resolution; andperforming an inspection operation on the inspection surface at aresolution at least equal to the inspection resolution.

One or more certain further aspects of the example method may beincorporated in certain embodiments. Performing the inspection operationmay include interrogating the inspection surface acoustically utilizingthe plurality of horizontally distributed sensors. The plurality ofhorizontally distributed sensors may be provided on a first payload ofthe inspection robot, and wherein the configuring the inspection robotfurther enhances at least one of a horizontal sensing resolution or avertical sensing resolution of the inspection robot by providing asecond plurality of horizontally distributed sensors on a second payloadof the inspection robot. The inspection robot may include providing thefirst payload defining a first horizontal inspection lane and the secondpayload defining a second horizontal inspection lane. The inspectionrobot may include providing the first payload and the second payloadsuch that the first horizontal inspection lane is distinct from thesecond horizontal inspection lane. The inspection robot may includeproviding the first payload and the second payload such that the firsthorizontal inspection lane at least partially overlaps the secondhorizontal inspection lane. The inspection robot may include determiningan inspection trajectory of the inspection robot over the inspectionsurface, such as the inspection trajectory determining a firstinspection run and a second inspection run, wherein a first area of theinspection surface traversed by the first inspection run at leastpartially overlaps a second area of the inspection surface traversed bythe second inspection run.

An example system includes an inspection robot including at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; and a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,and wherein the plurality of sleds are distributed horizontally acrossthe payload.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The plurality of sleds may bedistributed across the payload with a spacing defining a selectedhorizontal sensing resolution of the inspection robot. The sleds may bedistributed across the payload, wherein a plurality of sleds areprovided within a horizontal distance that is less than a horizontalwidth of a pipe to be inspected. There may be a plurality of sensors,wherein each sensor is mounted to a corresponding one of the sleds suchthat the sensor is operationally couplable to an inspection surface incontact with a bottom surface of the corresponding one of the sleds. Atleast one payload may include a first payload and a second payload, andwherein the first payload and the second payload define distincthorizontal inspection lanes for the inspection surface. There may be aplurality of sensors including ultra-sonic sensors, and wherein each ofthe plurality of payloads comprises a single couplant connection to theinspection robot.

An example system includes an inspection robot having a number ofsensors operationally coupled thereto; and a means for horizontallydistributing the number of sensors across a selected horizontalinspection lane of an inspection surface. In a further aspect, aplurality of the number of sensors may be provided to inspect a singlepipe of the inspection surface at a plurality of distinct horizontalpositions of the pipe.

An example system includes an inspection robot comprising a firstpayload and a second payload; a first plurality of arms pivotallymounted to the first payload, and a second plurality of arms pivotallymounted to the second payload; a first plurality of sleds mounted tocorresponding ones of the first plurality of arms, and a secondplurality of sleds mounted to corresponding ones of the second pluralityof arms; wherein the first payload defines a first horizontal inspectionlane for an inspection surface, and wherein the second payload defines asecond horizontal inspection lane for the inspection surface; andwherein the first horizontal inspection lane at least partially overlapsthe second horizontal inspection lane.

One or more certain further aspects of the example system may beincorporated in certain embodiments. At least one of the secondplurality of sleds may be horizontally aligned with at least one of thefirst plurality of sleds. There may be a plurality of sensors, whereineach sensor is mounted to a corresponding one of the first plurality ofsleds and the second plurality of sleds, such that the sensor isoperationally couplable to an inspection surface in contact with abottom surface of the corresponding one of the first plurality of sledsand the second plurality of sleds. Sensors may be mounted on thehorizontally aligned sleds for interrogating vertically distinctportions of the inspection surface. At least one of the second pluralityof sleds and at least one of the first plurality of sleds may behorizontally offset. The first payload may include a forward payload andwherein the second payload comprises a rear payload. The first payloadmay include a forward payload and wherein the second payload comprises atrailing payload.

An example apparatus includes an inspection data circuit structured tointerpret lead inspection data from a lead sensor; a sensorconfiguration circuit structured to determine a configuration adjustmentfor a trailing sensor in response to the lead inspection data; and asensor operation circuit structured to adjust at least one parameter ofthe trailing sensor in response to the configuration adjustment.

One or more certain further aspects of the example apparatus may beincorporated in certain embodiments. The inspection data circuit may befurther structured to interpret trailing sensor data from a trailingsensor, wherein the trailing sensor is responsive to the configurationadjustment. The configuration adjustment may include at least oneadjustment selected from the adjustments consisting of: changing ofsensing parameters of the trailing sensor; changing a cut-off time toobserve a peak value for an ultra-sonic trailing sensor; enablingoperation of a trailing sensor; adjusting a sensor sampling rate of atrailing sensor; adjusting a fault cut-off values for a trailing sensor;adjusting a sensor range of a trailing sensor; adjusting a resolutionvalue of a trailing sensor; changing a movement speed of an inspectionrobot, wherein the trailing sensors are operationally coupled to theinspection robot. The lead sensor and the trailing sensor may beoperationally coupled to an inspection robot. The lead sensor mayinclude a first sensor during a first inspection run, and wherein thetrailing sensor comprises the first sensor during a second inspectionrun. The inspection data circuit may be further structured to interpretthe lead inspection data and interpret the trailing sensor data in asingle inspection run.

An example system may include an inspection robot; a lead sensoroperationally coupled to the inspection robot and structured to providelead inspection data; a controller, the controller including: aninspection data circuit structured to interpret the lead inspectiondata; a sensor configuration circuit structured to determine aconfiguration adjustment for a trailing sensor in response to the leadinspection data; and a sensor operation circuit structured to adjust atleast one parameter of the trailing sensor in response to theconfiguration adjustment; and a trailing sensor responsive to theconfiguration adjustment.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The controller may be at leastpartially positioned on the inspection robot. The inspection datacircuit may be further structured to interpret trailing inspection datafrom the trailing sensor. The configuration adjustment may include atleast one adjustment selected from the adjustments consisting of:changing of sensing parameters of the trailing sensor; wherein thetrailing sensor comprises an ultra-sonic sensor, and changing a cut-offtime to observe a peak value for the trailing sensor; enabling operationof the trailing sensor; adjusting a sensor sampling rate of the trailingsensor; adjusting a fault cut-off values for the trailing sensor;adjusting a sensor range of the trailing sensor; adjusting a resolutionvalue of the trailing sensor; changing a movement speed of theinspection robot, wherein the trailing sensor is operationally coupledto the inspection robot. The trailing sensor may be operationallycoupled to an inspection robot. The lead sensor may include a firstsensor during a first inspection run, and wherein the trailing sensorcomprises the first sensor during a second inspection run. Theinspection data circuit may be further structured to interpret the leadinspection data and interpret the trailing inspection data in a singleinspection run.

An example method may include interpreting a lead inspection data from alead sensor; determining a configuration adjustment for a trailingsensor in response to the lead inspection data; and adjusting at leastone parameter of a trailing sensor in response to the configurationadjustment.

One or more certain further aspects of the example method may beincorporated in certain embodiments. A trailing inspection data may beinterpreted from the trailing sensor. The adjusting the at least oneparameter of the trailing sensor may include at least one adjustmentselected from the adjustments consisting of: changing of sensingparameters of the trailing sensor; changing a cut-off time to observe apeak value for an ultra-sonic trailing sensor; enabling operation of atrailing sensor; adjusting a sensor sampling rate of a trailing sensor;adjusting a fault cut-off values for a trailing sensor; adjusting asensor range of a trailing sensor; adjusting a resolution value of atrailing sensor; changing a movement speed of an inspection robot,wherein the trailing sensors are operationally coupled to the inspectionrobot. Interpreting the lead sensor data may be provided during a firstinspection run, and interpreting the trailing inspection data during asecond inspection run. Interpreting the lead inspection data andinterpreting the trailing inspection data may be performed in a singleinspection run.

An example method includes accessing an industrial system comprising aninspection surface, wherein the inspection surface comprises a personnelrisk feature; operating an inspection robot to inspect at least aportion of the inspection surface; and wherein the operating theinspection is performed with at least a portion of the industrial systemproviding the personnel risk feature still operating.

One or more certain further aspects of the example method may beincorporated in certain embodiments. The personnel risk feature mayinclude a portion of the inspection surface having an elevated height.The elevated height may include at least one height value consisting ofthe height values selected from: at least 10 feet, at least 20 feet, atleast 30 feet, greater than 50 feet, greater than 100 feet, and up to150 feet. The personnel risk feature may include an elevated temperatureof at least a portion of the inspection surface. The personnel riskfeature may include an enclosed space, and wherein at least a portion ofthe inspection surface is positioned within the enclosed space. Thepersonnel risk feature may include an electrical power connection.Determining a position of the inspection robot within the industrialsystem during the operating the inspection robot, and shutting down onlya portion of the industrial system during the inspection operation inresponse to the position of the inspection robot.

An example system includes an inspection robot comprising a payload; aplurality of arms, wherein each of the plurality of arms is pivotallymounted to the payload; and a plurality of sleds, wherein each sled ispivotally mounted to one of the plurality of arms, thereby configuring ahorizontal distribution of the plurality of sleds.

One or more certain further aspects of the example system may beincorporated in certain embodiments. There may be a plurality ofsensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds. The horizontal distribution of the plurality of sleds may providefor a selected horizontal resolution of the plurality of sensors. Acontroller may be configured to determine the selected horizontalresolution and to configure a position of the plurality of arms on thepayload in response to the selected horizontal resolution. Thehorizontal distribution of the plurality of sleds may provide foravoidance of an obstacle on an inspection surface to be traversed by theinspection robot. A controller may be configured to configure a positionof the plurality of arms on the payload in response to the obstacle onthe inspection surface, and to further configure the position of theplurality of arms on the payload in response to a selected horizontalresolution after the inspection robot clears the obstacle.

An example method includes determining at least one of an obstacleposition on an inspection surface and a selected horizontal resolutionfor sensors to be utilized for operating an inspection robot on aninspection surface; and configuring a horizontal distribution of aplurality of sleds on a payload of the inspection robot in response tothe at least one of the obstacle position and the selected horizontalresolution.

One or more certain further aspects of the example method may beincorporated in certain embodiments. The configuring of the horizontaldistribution may be performed before an inspection run of the inspectionrobot on the inspection surface. The configuring of the horizontaldistribution may be performed during inspection operations of theinspection robot on the inspection surface.

An example system includes an inspection robot including at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,and wherein the plurality of sleds are distributed horizontally acrossthe payload; and wherein a plurality of the sleds are provided within ahorizontal distance that is less than a horizontal width of a pipe to beinspected.

One or more certain further aspects of the example system may beincorporated in certain embodiments. An acoustic sensor may be mountedto each of the plurality of sleds provided within the horizontaldistance less than a horizontal width of the pipe to be inspected. Theplurality of sleds may be provided within the horizontal distance lessthan a horizontal width of the pipe to be inspected oriented such thateach of the acoustic sensors is perpendicularly oriented toward the pipeto be inspected. A sensor mounted to each of the plurality of sleds maybe provided within the horizontal distance less than a horizontal widthof the pipe to be inspected. The plurality of sleds may be providedwithin the horizontal distance less than a horizontal width of the pipeto be inspected oriented such that each of the sensors isperpendicularly oriented toward the pipe to be inspected.

An example system includes an inspection robot including at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms;and a plurality of sensors mounted on each of the plurality of sleds.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The plurality of sensors on each ofthe plurality of sleds may be vertically separated. A vertically forwardone of the plurality of sensors may be mounted on each of the pluralityof sleds comprises a lead sensor, and wherein a vertically rearward oneof the plurality of sensors comprises a trailing sensor.

An example system includes a first payload having a first plurality ofsensors mounted thereupon, and a second payload having a secondplurality of sensors mounted thereupon; an inspection robot; and one ofthe first payload and the second payload mounted upon the inspectionrobot, thereby defining a sensor suite for the inspection robot.

One or more certain further aspects of the example system may beincorporated in certain embodiments. A mounted one of the first payloadand the second payload may include a single couplant connection to theinspection robot. A mounted one of the first payload and the secondpayload may include a single electrical connection to the inspectionrobot.

An example method includes determining a sensor suite for inspectionoperations of an inspection robot; selecting a payload for theinspection robot from a plurality of available payloads in response tothe determined sensor suite; and mounting the selected payload to theinspection robot.

One or more certain further aspects of the example method may beincorporated in certain embodiments. The inspection operations may beperformed with the inspection robot after the mounting. The mounting maycomprise connecting a single couplant connection between the selectedpayload and the inspection robot. The mounting may include connecting asingle electrical connection between the selected payload and theinspection robot. The mounting may include dis-mounting a previouslymounted payload from the inspection robot before the mounting, where thedis-mounting may disconnect a single couplant connection between thepreviously mounted payload and the inspection robot, disconnect a singleelectrical connection between the previously mounted payload and theinspection robot, and the like. The mounting may include connecting asingle electrical connection between the selected payload and theinspection robot.

An example system includes an inspection robot comprising a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is pivotally mounted to one of the plurality ofarms; a plurality of sensors, wherein each sensor is mounted to acorresponding one of the sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds; and a biasing member disposed withineach of the sleds, wherein the biasing member provides a down force tothe corresponding one of the plurality of sensors.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The biasing member may include atleast one member selected from the members consisting of a leaf spring,a cylindrical spring, a torsion spring, and an electromagnet. Acontroller may be configured to adjust a biasing strength of the biasingmember. The controller may be further configured to interpret a distancevalue between the corresponding one of the plurality of sensors and aninspection surface, and to further adjust the biasing strength of thebiasing member in response to the distance value.

An example method includes providing a fixed acoustic path between asensor coupled to an inspection robot and an inspection surface; fillingthe acoustic path with a couplant; and acoustically interrogating theinspection surface with the sensor.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The filling of the acoustic pathwith the couplant may include injecting the couplant into the fixedacoustic path from a vertically upper direction. Determining that thesensor should be re-coupled to the inspection surface. Performing are-coupling operation in response to the determining. Lifting the sensorfrom the inspection surface, and returning the sensor to the inspectionsurface. Increasing a flow rate of the filling the acoustic path withthe couplant. Performing at least one operation selected from theoperations consisting of: determining that a predetermined time haselapsed since a last re-coupling operation; determining that an eventhas occurred indicating that a re-coupling operation is desired; anddetermining that the acoustic path has been interrupted.

An example system includes an inspection robot, and a plurality of sledsmounted to the inspection robot; a plurality of sensors, wherein eachsensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds; a couplantchamber disposed within each of the plurality of sleds, each couplantchamber interposed between a transducer of the sensor mounted to thesled and the inspection surface; wherein each couplant chamber comprisesa cone, the cone comprising a cone tip portion at an inspection surfaceend of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

One or more certain further aspects of the example system may beincorporated in certain embodiments, such as a plurality of payloads maybe mounted to the inspection robot; a plurality of arms, wherein each ofthe plurality of arms is pivotally mounted to one of the plurality ofpayloads; wherein the plurality of sleds are each mounted to one of theplurality of arms; and a biasing member coupled to at least one of: oneof the payloads or one of the arms; and wherein the biasing memberprovides a down force on one of the sleds corresponding to the one ofthe payloads or the one of the arms.

An example system includes an inspection robot, and a plurality of sledsmounted to the inspection robot; a plurality of sensors, wherein eachsensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds; a couplantchamber disposed within each of the plurality of sleds, each couplantchamber interposed between a transducer of the sensor mounted to thesled and the inspection surface; and a means for providing a low fluidloss of couplant from each couplant chamber.

An example system includes an inspection robot having a number of sledsmounted to the inspection robot (e.g., mounted on arms coupled topayloads). The example system further includes a number of sensors,where each sensor is mounted on one of the sleds—although in certainembodiments, each sled may have one or more sensors, or no sensors. Theexample system includes the sensors mounted on the sleds such that thesensor is operationally couplable to the inspection surface when abottom surface of the corresponding sled is in contact with theinspection surface. For example, the sled may include a holetherethrough, a chamber such that when the sensor is mounted in thechamber, the sensor is in a position to sense parameters about theinspection surface, or any other orientation as described throughout thepresent disclosure. The example system further includes a couplantchamber disposed within a number of the sleds—for example in two or moreof the sleds, in a horizontally distributed arrangement of the sleds,and/or with a couplant chamber disposed in each of the sleds. In certainembodiments, sleds may alternate with sensor arrangements—for example amagnetic induction sensor in a first sled, an acoustic sensor with acouplant chamber in a second sled, another magnetic induction sensor inthird sled, an acoustic sensor with a couplant chamber in a fourth sled,and so forth. Any pattern or arrangement of sensors is contemplatedherein. In certain embodiments, a magnetic induction sensor ispositioned in a forward portion of a sled (e.g., as a lead sensor) andan acoustic sensor is positioned in a middle or rearward portion of thesled (e.g., as a trailing sensor). In certain embodiments, arms forsleds having one type of sensor are longer and/or provide for a moreforward position than arms for sleds having a second type of sensor.

The example system further includes each couplant chamber provided as acone, with the cone having a cone tip portion at an inspection surfaceend of the cone, and a sensor mounting end opposite the inspectionsurface end. An example cone tip portion defines a couplant exitopening. An example system further includes a couplant entry for eachcouplant chamber, which may be positioned between the cone tip portionand the sensor mounting end. In certain embodiments, the couplant entryis positioned at a vertically upper side of the cone in an intendedorientation of the inspection robot on the inspection surface. Forexample, if the inspection robot is intended to be oriented on a flathorizontal inspection surface, the couplant entry may be positionedabove the cone or at an upper end of the cone. In another example, ifthe inspection robot is intended to be oriented on a vertical inspectionsurface, the couplant entry may be positioned on a side of the cone,such as a forward side (e.g., for an ascending inspection robot) or arearward side (e.g., for a descending inspection robot). The verticalorientation of the couplant entry, where present, should not be confusedwith a vertical or horizontal arrangement of the inspection robot (e.g.,for sensor distribution orientations). In certain embodiments, ahorizontal distribution of sensors is provided as perpendicular, and/orat an oblique angle, to a travel path of the inspection robot, which maybe vertical, horizontal, or at any other angle in absolute geometricspace.

Certain further aspects of an example system are described following,any one or more of which may be present in certain embodiments. Anexample system includes a controller 802 configured to fill the couplantchamber with a couplant—for example by providing a couplant command(e.g., flow rate, couplant rate, injection rate, and/or pump speedcommand) to a couplant pump which may be present on the inspection robotand/or remote from the inspection robot (e.g., providing couplantthrough a tether). In certain embodiments, the couplant pump isresponsive to the couplant command to provide the couplant, to theinspection robot, to a payload, and/or to individual sleds (and therebyto the couplant chamber via the couplant chamber entry). In certainembodiments, the couplant command is a couplant injection command, andthe couplant pump is responsive to the injection command to inject thecouplant into the couplant chamber. In certain embodiments, thecontroller is further configured to determine that at least one of thesensors should be re-coupled to the inspection surface. Example andnon-limiting operations to determine that at least one of the sensorsshould be re-coupled to the inspection surface include: determining thata predetermined time has elapsed since a last re-coupling operation;determining that an event has occurred indicating that a re-couplingoperation is desired; and/or determining that the acoustic path has beeninterrupted. In certain embodiments, the controller provides are-coupling instruction in response to determining that one or moresensors should be re-coupled to the inspection surface. Example andnon-limiting re-coupling instructions include a sensor lift command—forexample to lift the sensor(s) of a payload and/or arm briefly to clearbubbles from the couplant chamber. In certain embodiments, an actuatorsuch as a motor, push-rod, and/or electromagnet, is present on theinspection robot to lift a payload, an arm, and/or tilt a sled inresponse to the sensor lift command. In certain embodiments, ramps orother features on a sled are configured such that the sled lifts (ortilts) or otherwise exposes the couplant exit opening—for example inresponse to a reversal of the direction of motion for the inspectionrobot. In a further embodiment, the inspection robot is responsive tothe sensor lift command to briefly change a direction of motion andthereby perform the re-coupling operation. In certain embodiments, thecontroller is configured to provide the re-coupling instruction as anincreased couplant injection command—for example to raise the couplantflow rate through the couplant chamber and thereby clear bubbles ordebris.

An example procedure includes an operation to provide a fixed acousticpath (e.g., a delay line) between a sensor coupled to an inspectionrobot and an inspection surface. The example procedure includes anoperation to fill the acoustic path with couplant, and to acousticallyinterrogate the inspection surface with the sensor. Certain furtheraspects of the example procedure are described following, any one ormore of which may be present in certain embodiments. An exampleprocedure further includes an operation to fill the acoustic path withthe couplant by injecting the couplant into the fixed acoustic path froma vertically upper direction. An example procedure further includes anoperation to determine that the sensor should be re-coupled to thesurface, and/or to perform a re-coupling operation in response to thedetermining. In certain further embodiments, example operations toperform a re-coupling operation include at least: lifting the sensorfrom the inspection surface, and returning the sensor to the inspectionsurface; and/or increasing a flow rate of the filling of the acousticpath with the couplant. Example operations to determine the sensorshould be re-coupled to the surface include at least: determining that apredetermined time has elapsed since a last re-coupling operation;determining that an event has occurred indicating that a re-couplingoperation is desired; and determining that the acoustic path has beeninterrupted.

An example procedure includes performing an operation to determine aninspection resolution for an inspection surface (e.g., by determining alikely resolution that will reveal any features of interest such asdamage or corrosion, and/or to meet a policy or regulatory requirement);an operation to configure an inspection robot by providing a number ofhorizontally distributed acoustic sensors operationally coupled to theinspection robot (e.g., mounted to be moved by the inspection robot,and/or with couplant or other fluid provisions, electrical or otherpower provisions, and/or with communication provisions); an operation toprovide a fixed acoustic path between the acoustic sensors and theinspection surface; an operation to fill the acoustic path with acouplant; and an operation to perform an inspection operation on theinspection surface with the acoustic sensors. It will be understood thatadditional sensors beyond the acoustic sensors may be operationallycoupled to the inspection robot in addition to the acoustic sensors.

Certain further aspects of an example procedure are described following,any one or more of which may be present in certain embodiments. Anexample procedure includes an operation to perform the inspectionoperation on the inspection surface at a resolution at least equal to aninspection resolution, and/or where the inspection resolution is smaller(e.g., higher resolution) than a spacing of the horizontally distributedacoustic sensors (e.g., the procedure provides for a greater resolutionthan that provided by the horizontally spacing of the sensors alone). Anexample procedure includes the operation to fill the acoustic path withthe couplant including injecting the couplant into the fixed acousticpath from a vertically upper direction, and/or an operation to determinethat at least one of the acoustic sensors should be re-coupled to theinspection surface.

An example system includes an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface; wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions; wherein theenclosure portions extend past the magnetic hub portion and therebyprevent contact of the magnetic hub portion with the inspection surface.

One or more certain further aspects of the example system may beincorporated in certain embodiments. The enclosure portions may define achannel therebetween. A shape of the channel may be provided in responseto a shape of a feature on the inspection surface. The shape of thechannel may correspond to a curvature of the feature of the inspectionsurface. An outer covering for each of the enclosure portions may beprovided, such as where the outer covering for each of the enclosureportions define a channel therebetween. The ferrous enclosure portionsmay include one of an outer chamfer and an outer curvature, and whereinthe one of the outer chamfer and the outer curvature correspond to ashape of a feature on the inspection surface. The enclosure portions mayinclude ferrous enclosure portions.

An example system includes an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface; wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions; and whereinthe inspection robot further comprises a gear box motively coupled to atleast one of the wheels, and wherein the gear box comprises at least onethrust washer axially interposed between two gears of the gear box.

An example system includes an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface; wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions; and whereinthe inspection robot further comprises a gear box motively coupled to atleast one of the wheels, and wherein the gear box comprises gears thatare not a ferromagnetic material.

An example system includes an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface; wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions; and whereinthe inspection robot further comprises a gear box motively coupled to atleast one of the wheels, and a means for reducing magnetically inducedaxial loads on gears of the gear box.

An example system includes an inspection robot, and a plurality of sledsmounted to the inspection robot; a plurality of acoustic sensors,wherein each acoustic sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; and a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of theacoustic sensor mounted to the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include a couplant entry for the couplantchamber, wherein the couplant entry is positioned between the cone tipportion and the sensor mounting end.

An example system may further include wherein the couplant entry ispositioned at a vertically upper side of the cone when the inspectionrobot is positioned on the inspection surface.

An example system may further include wherein each sled includes acouplant connection conduit, wherein the couplant connection conduit iscoupled to a payload couplant connection at an upstream end, and coupledto the couplant entry of the cone at a downstream end.

An example method includes providing a sled for an inspection robot, thesled including an acoustic sensor mounted thereon and a couplant chamberdisposed within the sled, and the couplant chamber having a couplantentry; coupling the sled to a payload of the inspection robot at anupstream end of a couplant connection conduit, the couplant connectionconduit coupled to the couplant entry at a downstream end.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include de-coupling the sled from thepayload of the inspection robot, and coupling a distinct sled to thepayload of the inspection robot, without disconnecting the couplantconnection conduit from the couplant entry.

An example apparatus includes a controller, the controller including: aposition definition circuit structured to interpret position informationfor an inspection robot on an inspection surface; a data positioningcircuit structured to interpret inspection data from the inspectionrobot, and to correlate the inspection data to the position informationto determine position informed inspection data; and wherein the datapositioning circuit is further structured to provide the positioninformed inspection data as one of additional inspection data or updatedinspection data.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the positioninformation includes one of relative position information or absoluteposition information.

An example apparatus may further include wherein the position definitioncircuit is further structured to determine the position informationaccording to at least one of: global positioning service (GPS) data; anultra-wide band radio frequency (RF) signal; a LIDAR measurement; a deadreckoning operation; a relationship of the inspection robot position toa reference point; a barometric pressure value; and a known sensed valuecorrelated to a position of the inspection robot.

An example apparatus may further include wherein the position definitioncircuit is further structured to interpret a plant shape value, todetermine a definition of a plant space including the inspection surfacein response to the plant shape value, and to correlate the inspectiondata with a plant position information (e.g., into plant positionvalues) in response to the definition of the plant space and theposition information.

An example method includes: interpreting position information for aninspection robot on an inspection surface; interpreting inspection datafrom the inspection robot; correlating the inspection data to theposition information to determine position informed inspection data; andproviding the position informed inspection data as one of additionalinspection data or updated inspection data.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include updating the position informationfor the inspection robot, and correcting the position informedinspection data.

An example method may further include wherein the position informationincludes position information determined at least partially in responseto a dead reckoning operation, and wherein the updated positioninformation is determined at least partially in response to feedbackposition operation.

An example method may further include determining a plant definitionvalue, and to determine plant position values in response to the plantdefinition value and the position information.

An example method may further include providing the position informedinspection data further in response to the plant position values.

An example apparatus includes: an inspection data circuit structured tointerpret inspection data from an inspection robot on an inspectionsurface; a robot positioning circuit structured to interpret positiondata for the inspection robot; and an inspection visualization circuitstructured to determine an inspection map in response to the inspectiondata and the position data, and to provide at least a portion of theinspection map for display to a user.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the inspectionvisualization circuit is further responsive structured to interpret auser focus value, and to update the inspection map in response to theuser focus value.

An example apparatus may further include wherein the inspectionvisualization circuit is further responsive structured to interpret auser focus value, and to provide focus data in response to the userfocus value.

An example apparatus may further include wherein the inspection mapincludes a physical depiction of the inspection surface.

An example apparatus may further include the inspection map furtherincludes a visual representation of at least a portion of the inspectiondata depicted on the inspection surface.

An example apparatus may further include wherein the inspection mapincludes a virtual mark for a portion of the inspection surface.

An example apparatus includes: an acoustic data circuit structured tointerpret return signals from an inspection surface to determine rawacoustic data; a thickness processing circuit structured to determine aprimary mode score value in response to the raw acoustic data, and inresponse to the primary mode score value exceeding a predeterminedthreshold, determining a primary mode value corresponding to a thicknessof the inspection surface material.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the thicknessprocessing circuit is further structured to determine, in response tothe primary mode score value not exceeding the predetermined threshold,a secondary mode score value in response to the raw acoustic data.

An example apparatus may further include wherein the thicknessprocessing circuit is further structured to determine, in response tothe secondary mode score value exceeding a threshold, a secondary modevalue corresponding to a thickness of the inspection surface material.

An example apparatus may further include wherein the thicknessprocessing circuit is further structured to determine the primary modescore value in response to at least one parameter selected from theparameters consisting of: a time of arrival for a primary return; a timeof arrival for a secondary return; a character of a peak for the primaryreturn; a character of a peak for the secondary return; a sensoralignment determination for an acoustic sensor providing the returnsignals; a sled position for a sled having the acoustic sensor mountedthereupon; and a couplant anomaly indication.

An example apparatus may further include wherein the secondary modevalue including a value determined from a number of reflected peaks ofthe return signals.

An example apparatus may further include wherein the raw acoustic dataincludes a lead inspection data, the apparatus further including: asensor configuration circuit structured to determine a configurationadjustment for a trailing sensor in response to the lead inspectiondata; and a sensor operation circuit structured to adjust at least oneparameter of the trailing sensor in response to the configurationadjustment; and a trailing sensor responsive to the configurationadjustment.

An example apparatus may further include wherein the acoustic datacircuit is further structured to interpret trailing inspection data fromthe trailing sensor.

An example apparatus may further include wherein the configurationadjustment includes at least one adjustment selected from theadjustments consisting of: changing of sensing parameters of thetrailing sensor; wherein the trailing sensor includes an ultra-sonicsensor, and changing a cut-off time to observe a peak value for thetrailing sensor; enabling operation of the trailing sensor; adjusting asensor sampling rate of the trailing sensor; adjusting a fault cut-offvalue for the trailing sensor; adjusting a sensor range of the trailingsensor; adjusting a resolution value of the trailing sensor; changing amovement speed of an inspection robot, wherein the trailing sensor isoperationally coupled to the inspection robot.

An example apparatus may further include wherein a lead sensor providingthe lead inspection data includes a first sensor during a firstinspection run, and wherein the trailing sensor includes the firstsensor during a second inspection run.

An example apparatus may further include wherein the acoustic datacircuit is further structured to interpret the lead inspection data andinterpret the trailing inspection data in a single inspection run.

An example apparatus may further include the wherein the raw acousticdata includes a lead inspection data, the apparatus further including: asensor configuration circuit structured to determine a configurationadjustment in response to the lead inspection data, and wherein theconfiguration includes an instruction to utilize at least one of aconsumable, a slower, or a more expensive trailing operation in responseto the lead inspection data.

An example apparatus may further include wherein the trailing operationincludes at least one operation selected from the operations consistingof: a sensing operation; a repair operation; and a marking operation.

An example apparatus includes: an electromagnetic (EM) data circuitstructured to interpret EM induction data provided by a magneticinduction sensor; a substrate distance circuit structured to determine asubstrate distance value between the magnetic induction sensor and aferrous substrate of an inspection surface; and an EM diagnostic circuitstructured to provide a diagnostic value in response to the substratedistance value.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the diagnostic valueincludes at least one value selected from the values consisting of: arationality check indicating whether the sensor is positioned inproximity to the inspection surface; and a sensor position valueindicating a distance from a second sensor to the substrate of theinspection surface.

An example apparatus may further include: an acoustic data circuitstructured to interpret return signals from the inspection surface todetermine raw acoustic data; a thickness processing circuit structuredto: determine a primary mode score value in response to the raw acousticdata and further in response to the rationality check; and in responseto the primary mode score value exceeding a predetermined threshold,determining a primary mode value corresponding to a thickness of theinspection surface material.

An example apparatus may further include: an acoustic data circuitstructured to interpret return signals from the inspection surface todetermine raw acoustic data; a thickness processing circuit structuredto: determine a primary mode score value in response to the raw acousticdata and further in response to the sensor position value; and inresponse to the primary mode score value exceeding a predeterminedthreshold, determining a primary mode value corresponding to a thicknessof the inspection surface material.

An example apparatus may further include: an acoustic data circuitstructured to interpret return signals from the inspection surface todetermine raw acoustic data; a thickness processing circuit structuredto: determine a primary mode score value in response to the raw acousticdata and further in response to the diagnostic value; and in response tothe primary mode score value exceeding a predetermined threshold,determining a primary mode value corresponding to a thickness of theinspection surface material.

An example method includes: determining an induction processingparameter; and adjusting an inspection plan for an inspection robot inresponse to the induction processing parameter.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the induction processingparameter includes at least one parameter selected from the parametersconsisting of: a substrate distance value, a sensor position value, anda rationality diagnostic value.

An example method may further include wherein the adjusting theinspection plan includes at least one operation selected from theoperations consisting of: adjusting a sensor calibration value;adjusting a trailing sensor calibration value; adjusting an inspectionresolution value for a sensor used in the inspection plan; adjusting atleast one of a number, a type, or a positioning of a plurality ofsensors used in the inspection plan; adjusting an inspection trajectoryof the inspection robot; adjusting a sled ramp configuration for theinspection robot; adjusting a down force for a sled of the inspectionrobot; and adjusting a down force for a sensor of the inspection robot.

An example method may further include performing an additionalinspection operation in response to the induction processing parameter.

An example method may further include wherein the adjusting includesadjusting an inspection trajectory of the inspection robot to follow adetected feature on an inspection surface.

An example method may further include wherein the detected featureincludes at least one feature selected from the features consisting of:a weld, a groove, a crack, and a coating difference area.

An example method may further include an operation to respond to thedetected feature.

An example method may further include wherein the operation to respondto the detected feature includes at least one operation selected fromthe operations consisting of: a repair operation; a treatment operation;a weld operation; an epoxy application operation; a cleaning operation;a marking operation; and a coating operation.

An example method may further include detecting a feature on theinspection surface, and marking the feature virtually on an inspectionmap.

An example method may further include detecting a feature on theinspection surface, and marking the feature with a mark not in thevisible spectrum.

An example method may further include wherein the marking furtherincludes utilizing at least one of an ultra-violet dye, a penetrant, anda virtual mark.

An example method includes: performing an inspection operation on aninspection surface, the inspection operation including an inspectionsurface profiling operation; determining a contour of at least a portionof the inspection surface in response to the surface profilingoperation; and adjusting a calibration of an ultra-sonic sensor inresponse to the contour.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the adjusting is performedas a post-processing operation.

An example method includes: performing an inspection operation on aninspection surface, the inspection operation including interrogating theinspection surface with an electromagnetic sensor; determining aninduction processing parameter in response to the interrogating; andadjusting a calibration of an ultra-sonic sensor in response to theinduction processing parameter.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the adjusting is performedas a post-processing operation.

An example method includes: interpreting inspection data from aninspection robot on an inspection surface; interpreting position datafor the inspection robot; and determining an inspection map in responseto the inspection data and the position data, and providing at least aportion of the inspection map for display to a user.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the inspection mapincludes at least one parameter selected from the parameters consistingof: how much material should be added to the inspection surface; and atype of repair that should be applied to the inspection surface.

An example method may further include wherein the inspection map furtherincludes an indication of a time until a repair of the inspectionsurface will be required.

An example method may further include accessing a facility wear model,and determining the time until a repair of the inspection surface willbe required in response to the facility wear model.

An example method may further include wherein the inspection map furtherincludes an indication a time that a repair of the inspection surface isexpected to last.

An example method may further include accessing a facility wear model,and determining the time that the repair of the inspection surface isexpected to last in response to the facility wear model.

An example method may further include determining the time that therepair of the inspection surface is expected to last in response to atype of repair to be performed.

An example method may further include presenting a user with a number ofrepair options, and further determining the time that the repair of theinspection surface is expected to last in response to a selected one ofthe number of repair options.

An example method includes accessing an industrial system comprising aninspection surface, wherein the inspection surface comprises a personnelrisk feature; operating an inspection robot to inspect at least aportion of the inspection surface, wherein the operating the inspectionis performed with at least a portion of the industrial system providingthe personnel risk feature still operating; interpreting positioninformation for the inspection robot on the inspection surface;interpreting inspection data from the inspection robot; correlating theinspection data to the position information to determine positioninformed inspection data; and providing the position informed inspectiondata as one of additional inspection data or updated inspection data.

An example system including an inspection robot with a sensorconfiguration circuit structured to determine a configuration adjustmentfor a trailing sensor in response to the lead inspection data; a sensoroperation circuit structured to adjust at least one parameter of thetrailing sensor in response to the configuration adjustment; and atrailing sensor responsive to the configuration adjustment, theinspection robot interpreting position information on an inspectionsurface, interpreting inspection data from the inspection robot,correlating the inspection data to the position information to determineposition informed inspection data, and providing the position informedinspection data as one of additional inspection data or updatedinspection data.

An example system including an inspection robot comprising at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,wherein the plurality of sleds are distributed horizontally across thepayload; and a plurality of sensors, wherein each sensor is mounted to acorresponding plurality of sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe plurality of sleds.

An example system including an inspection robot, and a plurality ofsleds mounted to the inspection robot; a plurality of acoustic sensors,wherein each acoustic sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; and a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of theacoustic sensor mounted to the sled and the inspection surface; theinspection robot providing a fixed acoustic path between a sensorcoupled to an inspection robot and an inspection surface, filling theacoustic path with a couplant, and acoustically interrogating theinspection surface with the sensor.

An example system including an inspection robot, and a plurality ofsleds mounted to the inspection robot; a plurality of acoustic sensors,wherein each acoustic sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of theacoustic sensor mounted to the sled and the inspection surface; whereineach couplant chamber comprises a cone, the cone comprising a cone tipportion at an inspection surface end of the cone, and a sensor mountingend opposite the cone tip portion, and wherein the cone tip portiondefines a couplant exit opening.

An example system including an inspection robot, and a plurality ofsleds mounted to the inspection robot; a plurality of sensors, whereineach sensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds; a couplantchamber disposed within each of the plurality of sleds, each couplantchamber interposed between a transducer of the sensor mounted to thesled and the inspection surface, wherein each couplant chamber comprisesa cone, the cone comprising a cone tip portion at an inspection surfaceend of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening; the inspection robot providing a fixed acoustic path between asensor coupled to an inspection robot and an inspection surface; fillingthe acoustic path with a couplant; and acoustically interrogating theinspection surface with the sensor.

A system, comprising: an inspection robot comprising a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, wherein each sled comprises an upper portion and a replaceablelower portion having a bottom surface, and a plurality of sensors,wherein each sensor is mounted to a corresponding one of the sleds suchthat the sensor is operationally couplable to an inspection surface incontact with a bottom surface of the corresponding one of the sleds.

An example system including an inspection robot comprising at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,and wherein the plurality of sleds are distributed horizontally acrossthe payload; an acoustic data circuit structured to interpret returnsignals from an inspection surface to determine raw acoustic data; athickness processing circuit structured to determine a primary modescore value in response to the raw acoustic data, and in response to theprimary mode score value exceeding a predetermined threshold,determining a primary mode value corresponding to a thickness of theinspection surface material.

An example system including an inspection robot comprising at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,and wherein the plurality of sleds are distributed horizontally acrossthe payload; an electromagnetic (EM) data circuit structured tointerpret EM induction data provided by a magnetic induction sensor; asubstrate distance circuit structured to determine a substrate distancevalue between the magnetic induction sensor and a ferrous substrate ofan inspection surface; and an EM diagnostic circuit structured toprovide a diagnostic value in response to the substrate distance value.

An example system including an inspection robot comprising a pluralityof payloads; a plurality of arms, wherein each of the plurality of armsis pivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is pivotally mounted to one of the plurality ofarms; a plurality of sensors, wherein each sensor is mounted to acorresponding one of the sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds; a biasing member disposed withineach of the sleds, wherein the biasing member provides a down force tothe corresponding one of the plurality of sensors; the inspection robotproviding a fixed acoustic path between a sensor coupled to aninspection robot and an inspection surface, filling the acoustic pathwith a couplant, and acoustically interrogating the inspection surfacewith the sensor.

An example system includes an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface; wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions; wherein theinspection robot further comprises a gear box motively coupled to atleast one of the wheels, and wherein the gear box comprises at least onethrust washer axially interposed between two gears of the gear box; andwherein the enclosure portions extend past the magnetic hub portion andthereby prevent contact of the magnetic hub portion with the inspectionsurface.

An example system including an inspection robot comprising a pluralityof payloads; a plurality of arms, wherein each of the plurality of armsis mounted to one of the plurality of payloads; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms;a plurality of sensors, wherein each sensor is mounted to acorresponding one of the sleds such that the sensor is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds, wherein each sled is pivotallymounted to one of the plurality of arms at a selected one of a pluralityof pivot point positions; and a controller configured to select the oneof the plurality of pivot point positions during an inspection run ofthe inspection robot, the controller configured to select the one of theplurality of pivot point positions in response to a travel direction ofthe inspection robot, wherein each sled is pivotally mounted to one ofthe plurality of arms at a plurality of pivot point positions.

An example system including an inspection data circuit structured tointerpret lead inspection data from a lead sensor; a sensorconfiguration circuit structured to determine a configuration adjustmentfor a trailing sensor in response to the lead inspection data; a sensoroperation circuit structured to adjust at least one parameter of thetrailing sensor in response to the configuration adjustment;

the system interpreting inspection data from an inspection robot on aninspection surface; interpreting position data for the inspection robot;and determining an inspection map in response to the inspection data andthe position data, and providing at least a portion of the inspectionmap for display to a user.

An example method including determining an inspection resolution for aninspection surface; configuring an inspection robot by providing aplurality of horizontally distributed sensors operationally coupled tothe inspection robot in response to the inspection resolution;performing an inspection operation on the inspection surface at aresolution at least equal to the inspection resolution, wherein theplurality of horizontally distributed sensors are provided on a firstpayload of the inspection robot, and wherein the configuring theinspection robot further comprises enhancing at least one of ahorizontal sensing resolution or a vertical sensing resolution of theinspection robot by providing a second plurality of horizontallydistributed sensors on a second payload of the inspection robot;interpreting inspection data from the inspection robot on an inspectionsurface; interpreting position data for the inspection robot; anddetermining an inspection map in response to the inspection data and theposition data, and providing at least a portion of the inspection mapfor display to a user.

An example system including an inspection robot comprising at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms;and a plurality of sensors mounted on each of the plurality of sleds;the inspection robot determining an induction processing parameter, andadjusting an inspection plan for an inspection robot in response to theinduction processing parameter.

An example system including an inspection robot comprising at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms;a plurality of sensors mounted on each of the plurality of sleds; aninspection data circuit structured to interpret lead inspection datafrom a lead sensor; a sensor configuration circuit structured todetermine a configuration adjustment for a trailing sensor in responseto the lead inspection data; and a sensor operation circuit structuredto adjust at least one parameter of the trailing sensor in response tothe configuration adjustment.

An example system including an inspection robot comprising a pluralityof payloads; a plurality of arms, wherein each of the plurality of armsis pivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is pivotally mounted to one of the plurality ofarms, and wherein each sled comprises a bottom surface; and a removablelayer positioned on each of the bottom surfaces;

the inspection robot determining an induction processing parameter, andadjusting an inspection plan for an inspection robot in response to theinduction processing parameter.

An example system including an inspection robot having a plurality ofwheels, wherein the plurality of wheels are positioned to engage aninspection surface when the inspection robot is positioned on theinspection surface, wherein each of the plurality of wheels comprises amagnetic hub portion interposed between enclosure portions, wherein theenclosure portions extend past the magnetic hub portion and therebyprevent contact of the magnetic hub portion with the inspection surface,the inspection robot providing a fixed acoustic path between a sensorcoupled to an inspection robot and an inspection surface, filling theacoustic path with a couplant, and acoustically interrogating theinspection surface with the sensor.

An example method includes: performing an inspection operation on aninspection surface, the inspection operation including an inspectionsurface profiling operation; detecting a feature on the inspectionsurface and marking the feature virtually on an inspection map;determining a contour of at least a portion of the inspection surface inresponse to the surface profiling operation; and adjusting a calibrationof an ultra-sonic sensor in response to the contour.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the inspection operationincludes interrogating the inspection surface with an electromagneticsensor; determining an induction processing parameter in response to theinterrogating; and further adjusting the calibration of the ultra-sonicsensor in response to the induction processing parameter.

An example method may further include wherein the detected featureincludes at least one feature selected from the features consisting of:a weld, a groove, a crack, and a coating difference area.

An example apparatus includes: an inspection data circuit structured tointerpret inspection data from an inspection robot on an inspectionsurface; a robot positioning circuit structured to interpret positiondata for the inspection robot; an electromagnetic (EM) data circuitstructured to interpret EM induction data provided by a magneticinduction sensor; a substrate distance circuit structured to determine asubstrate distance value between the magnetic induction sensor and aferrous substrate of an inspection surface; an EM diagnostic circuitstructured to provide a diagnostic value in response to the substratedistance value; and an inspection visualization circuit structured todetermine an inspection map in response to the inspection data and theposition data, and to provide at least a portion of the inspection mapfor display to a user.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the diagnostic valueincludes at least one value selected from the values consisting of: arationality check indicating whether the sensor is positioned inproximity to the inspection surface; and a sensor position valueindicating a distance from a second sensor to the substrate of theinspection surface.

An example apparatus may further include wherein the inspectionvisualization circuit is further responsively structured to interpret auser focus value, and to update the inspection map in response to theuser focus value.

An example method includes: determining an inspection resolution for aninspection surface; configuring an inspection robot by providing aplurality of horizontally distributed sensors operationally coupled tothe inspection robot in response to the inspection resolution;performing an inspection operation on the inspection surface at aresolution at least equal to the inspection resolution; interpretinginspection data from the inspection robot on the inspection surface;interpreting position data for the inspection robot; determining aninspection map in response to the inspection data and the position data;detecting a feature on the inspection surface and marking the featurevirtually on the inspection map; and providing at least a portion of theinspection map for display to a user.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the performing theinspection operation includes interrogating the inspection surfaceacoustically utilizing the plurality of horizontally distributedsensors.

An example apparatus includes: a controller, the controller including:an electromagnetic (EM) data circuit structured to interpret EMinduction data provided by a magnetic induction sensor; a substratedistance circuit structured to determine a substrate distance valuebetween the magnetic induction sensor and a ferrous substrate of aninspection surface; an EM diagnostic circuit structured to provide adiagnostic value in response to the substrate distance value; a positiondefinition circuit structured to interpret position information for aninspection robot on an inspection surface; and a data positioningcircuit to correlate the substrate distance values to the positioninformation to determine position informed substrate distance values andwherein the data positioning circuit is further structured to providethe position informed substrate distance values as one of additionalinspection data or updated inspection data.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the diagnostic valueincludes at least one value selected from the values consisting of: arationality check indicating whether the sensor is positioned inproximity to the inspection surface; and a sensor position valueindicating a distance from a second sensor to the substrate of theinspection surface.

An example apparatus may further include wherein the position definitioncircuit is further structured to determine the position informationaccording to at least one of: global positioning service (GPS) data; anultra-wide band radio frequency (RF) signal; a LIDAR measurement; a deadreckoning operation; a relationship of the inspection robot position toa reference point; a barometric pressure value; and a known sensed valuecorrelated to a position of the inspection robot.

An example apparatus includes: an acoustic data circuit structured tointerpret return signals from an inspection surface to determine rawacoustic data; a thickness processing circuit structured to determine aprimary mode score value in response to the raw acoustic data, and inresponse to the primary mode score value exceeding a predeterminedthreshold, determining a primary mode value corresponding to a thicknessof the inspection surface material; a robot positioning circuitstructured to interpret position data for the inspection robot; and aninspection visualization circuit structured to determine an inspectionmap in response to the thickness of the inspection surface material andthe position data, and to provide at least a portion of the inspectionmap for display to a user.

Certain further aspects of an example apparatus are described following,any one or more of which may be included in certain embodiments of theexample apparatus.

An example apparatus may further include wherein the inspectionvisualization circuit is further structured to determine an inspectionmap in response to the primary mode score value.

An example apparatus may further include wherein the thicknessprocessing circuit is further structured to determine, in response tothe primary mode score value not exceeding the predetermined threshold,a secondary mode score value in response to the raw acoustic data.

An example method includes: accessing an industrial system including aninspection surface, wherein the inspection surface includes a personnelrisk feature; operating an inspection robot to inspect at least aportion of the inspection surface, wherein the inspection robot has aplurality of wheels and wherein each of the plurality of wheels includesa magnetic hub portion interposed between enclosure portions, theenclosure portions extending past the magnetic hub portion and therebypreventing contact of the magnetic hub portion with the inspection surf;and wherein operating the inspection is performed with at least aportion of the industrial system providing the personnel risk featurestill operating.

Certain further aspects of an example method are described following,any one or more of which may be included in certain embodiments of theexample method.

An example method may further include wherein the personnel risk featureincludes at least one of a portion of the inspection surface having anelevated height, an elevated temperature of at least a portion of theinspection surface, a portion of the inspection surface is positionedwithin the enclosed space, and an electrical power connection.

An example method may further include determining a position of theinspection robot within the industrial system during the operating theinspection robot, and shutting down only a portion of the industrialsystem during the inspection operation in response to the position ofthe inspection robot.

An example system includes: an inspection robot including: a pluralityof payloads; a plurality of arms, wherein each of the plurality of armsis pivotally mounted to one of the plurality of payloads; and aplurality of sleds, wherein each sled is pivotally mounted to one of theplurality of arms, and wherein each sled includes a bottom surface; anda removable layer positioned on each of the bottom surfaces; and acontroller, the controller including: an electromagnetic (EM) datacircuit structured to interpret EM induction data provided by a magneticinduction sensor; a substrate distance circuit structured to determine asubstrate distance value between the magnetic induction sensor and aferrous substrate of an inspection surface; and an EM diagnostic circuitstructured to provide a diagnostic value in response to the substratedistance value.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein at least one of the sledsincludes a magnetic induction sensor.

An example system may further include wherein the removable layerincludes a thickness providing a selected spatial orientation between aninspection contact side of the removable layer and the bottom surface.

An example system may further include wherein the diagnostic valueincludes at least one value selected from the values consisting of: arationality check indicating whether the sensor is positioned inproximity to the inspection surface; and a sensor position valueindicating a distance from a second sensor to the substrate of theinspection surface.

An example system includes: an inspection robot including: at least onepayload; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to the at least one payload; a plurality of sleds,wherein each sled is pivotally mounted to one of the plurality of arms,and wherein the plurality of sleds are distributed horizontally acrossthe payload; and wherein the horizontal distribution of the plurality ofsleds provides for a selected horizontal resolution of the plurality ofsensors.

An example system includes: an inspection robot including: a payload; aplurality of arms, wherein each of the plurality of arms is pivotallymounted to the payload; a plurality of sleds, wherein each sled ispivotally mounted to one of the plurality of arms, thereby configuring ahorizontal distribution of the plurality of sleds; a plurality ofsensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; and a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of thesensor mounted to the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the horizontaldistribution of the plurality of sleds provides for a selectedhorizontal resolution of the plurality of sensors.

An example system may further include a controller configured todetermine the selected horizontal resolution and to configure a positionof the plurality of arms on the payload in response to the selectedhorizontal resolution.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system includes: an inspection robot; a plurality of sledsmounted to the inspection robot, wherein each sled is pivotally mountedat a selected one of a plurality of pivot point positions; a pluralityof sensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; and a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of thesensor mounted to the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include a controller configured to selectthe one of the plurality of pivot point positions during an inspectionrun of the inspection robot.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system includes an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is mounted to one of the plurality of arms at aselected one of a plurality of pivot point positions; a plurality ofsensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds; a couplant chamber disposed within each of the plurality ofsleds, each couplant chamber interposed between a transducer of thesensor mounted to the sled and the inspection surface; and a biasingmember coupled to each one of the plurality of arms, and wherein thebiasing member provides a biasing force to corresponding one of theplurality of sleds, wherein the biasing force is directed toward theinspection surface.

An example system includes: an inspection robot, and a plurality ofsleds mounted to the inspection robot; a plurality of sensors, whereineach sensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds, wherein thebottom surface of the corresponding one of the sleds is contoured inresponse to a shape of the inspection surface; and a couplant chamberdisposed within each of the plurality of sleds, each couplant chamberinterposed between a transducer of the sensor mounted to the sled andthe inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; a plurality ofsleds, wherein each sled is mounted to one of the plurality of arms; aplurality of sensors, wherein each sensor is mounted to a correspondingone of the sleds such that the sensor is operationally couplable to aninspection surface in contact with a bottom surface of the correspondingone of the sleds, wherein the bottom surface of the corresponding one ofthe sleds is contoured in response to a shape of the inspection surface;a couplant chamber disposed within each of the plurality of sleds, eachcouplant chamber interposed between a transducer of the sensor mountedto the sled and the inspection surface; and a biasing member coupled toeach one of the plurality of arms, and wherein the biasing memberprovides a biasing force to corresponding one of the plurality of sleds,wherein the biasing force is directed toward the inspection surface.

An example method includes: providing an inspection robot having aplurality of payloads and a corresponding plurality of sleds for each ofthe payloads, wherein the bottom surface of the corresponding one of thesleds is contoured in response to a shape of an inspection surface;mounting a sensor on each of the sleds, each sensor mounted to acouplant chamber interposed between the sensor and the inspectionsurface, and each couplant chamber including a couplant entry for thecouplant chamber; changing one of the plurality of payloads to adistinct payload; and wherein the changing of the plurality of payloadsdoes not include dismounting any of the sensors from correspondingcouplant chambers.

An example system includes an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled includes a bottom surface defining a rampand wherein each sled defines a chamber sized to accommodate a sensor.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each chamber furtherincludes a stop, and wherein each of the plurality of sensors ispositioned against the stop.

An example system may further include wherein each sensor positionedagainst the stop has a predetermined positional relationship with abottom surface of the corresponding one of the plurality of sleds.

An example system may further include wherein each sled further includesthe bottom surface defining two ramps, wherein the two ramps include aforward ramp and a rearward ramp.

An example system may further include wherein the ramp include at leastone of a ramp angle and a ramp total height value.

An example system may further include wherein the at least one of theramp angle and the ramp total height value are configured to traverse anobstacle on an inspection surface to be traversed by the inspectionrobot.

An example system includes: an inspection robot including a plurality ofpayloads; a plurality of arms, wherein each of the plurality of arms ispivotally mounted to one of the plurality of payloads; and a pluralityof sleds, wherein each sled is pivotally mounted to one of the pluralityof arms, and wherein each sled defines a chamber sized to accommodate asensor, and wherein the bottom surface of the corresponding one of thesleds is contoured in response to a shape of an inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein each chamber furtherincludes a stop, and wherein each of the plurality of sensors ispositioned against the stop.

An example system may further include wherein each sensor positionedagainst the stop has a predetermined positional relationship with abottom surface of the corresponding one of the plurality of sleds.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

An example system includes: an inspection robot including: a payload; aplurality of arms, wherein each of the plurality of arms is pivotallymounted to the payload; a plurality of sleds, wherein each sled ispivotally mounted to one of the plurality of arms, thereby configuring ahorizontal distribution of the plurality of sleds; a plurality ofsensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds, wherein the bottom surface of the corresponding one of the sledsis contoured in response to a shape of an inspection surface; and acouplant chamber disposed within each of the plurality of sleds, eachcouplant chamber interposed between a transducer of the sensor mountedto the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the horizontaldistribution of the plurality of sleds provides for a selectedhorizontal resolution of the plurality of sensors.

An example system may further include a controller configured todetermine the selected horizontal resolution and to configure a positionof the plurality of arms on the payload in response to the selectedhorizontal resolution.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

An example system includes: an inspection robot including: a payload; aplurality of arms, wherein each of the plurality of arms is pivotallymounted to the payload; a plurality of sleds, wherein each sled ispivotally mounted to one of the plurality of arms at a selected one of aplurality of pivot point positions; thereby configuring a horizontaldistribution of the plurality of sleds; a plurality of sensors, whereineach sensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds; and acouplant chamber disposed within each of the plurality of sleds, eachcouplant chamber interposed between a transducer of the sensor mountedto the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the horizontaldistribution of the plurality of sleds provides for a selectedhorizontal resolution of the plurality of sensors.

An example system may further include a controller configured todetermine the selected horizontal resolution and to configure a positionof the plurality of arms on the payload in response to the selectedhorizontal resolution.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system includes: an inspection robot; a plurality of sledsmounted to the inspection robot, wherein each sled is pivotally mountedat a selected one of a plurality of pivot point positions; a pluralityof sensors, wherein each sensor is mounted to a corresponding one of thesleds such that the sensor is operationally couplable to an inspectionsurface in contact with a bottom surface of the corresponding one of thesleds, wherein the bottom surface of the corresponding one of the sledsis contoured in response to a shape of an inspection surface; and acouplant chamber disposed within each of the plurality of sleds, eachcouplant chamber interposed between a transducer of the sensor mountedto the sled and the inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include a controller configured to selectthe one of the plurality of pivot point positions during an inspectionrun of the inspection robot.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

An example system includes: an inspection robot including: a payload; aplurality of arms, wherein each of the plurality of arms is pivotallymounted to the payload; a plurality of sleds, wherein each sled ispivotally mounted to one of the plurality of arms at a selected one of aplurality of pivot point positions; thereby configuring a horizontaldistribution of the plurality of sleds; a plurality of sensors, whereineach sensor is mounted to a corresponding one of the sleds such that thesensor is operationally couplable to an inspection surface in contactwith a bottom surface of the corresponding one of the sleds, wherein thebottom surface of the corresponding one of the sleds is contoured inresponse to a shape of an inspection surface; and a couplant chamberdisposed within each of the plurality of sleds, each couplant chamberinterposed between a transducer of the sensor mounted to the sled andthe inspection surface.

Certain further aspects of an example system are described following,any one or more of which may be included in certain embodiments of theexample system.

An example system may further include wherein the horizontaldistribution of the plurality of sleds provides for a selectedhorizontal resolution of the plurality of sensors.

An example system may further include a controller configured todetermine the selected horizontal resolution and to configure a positionof the plurality of arms on the payload in response to the selectedhorizontal resolution.

An example system may further include wherein each couplant chamberincludes a cone, the cone including a cone tip portion at an inspectionsurface end of the cone, and a sensor mounting end opposite the cone tipportion, and wherein the cone tip portion defines a couplant exitopening.

An example system may further include wherein the inspection surfaceincludes a pipe outer wall, and wherein the bottom surface of thecorresponding one of the sleds includes a concave shape.

An example system may further include wherein the bottom surface of thecorresponding one of the sleds includes at least one shape selected fromthe shapes consisting of: a concave shape, a convex shape, and a curvedshape.

The methods and systems described herein may be deployed in part or inwhole through a machine having a computer, computing device, processor,circuit, and/or server that executes computer readable instructions,program codes, instructions, and/or includes hardware configured tofunctionally execute one or more operations of the methods and systemsdisclosed herein. The terms computer, computing device, processor,circuit, and/or server, as utilized herein, should be understoodbroadly.

Any one or more of the terms computer, computing device, processor,circuit, and/or server include a computer of any type, capable to accessinstructions stored in communication thereto such as upon anon-transient computer readable medium, whereupon the computer performsoperations of systems or methods described herein upon executing theinstructions. In certain embodiments, such instructions themselvescomprise a computer, computing device, processor, circuit, and/orserver. Additionally or alternatively, a computer, computing device,processor, circuit, and/or server may be a separate hardware device, oneor more computing resources distributed across hardware devices, and/ormay include such aspects as logical circuits, embedded circuits,sensors, actuators, input and/or output devices, network and/orcommunication resources, memory resources of any type, processingresources of any type, and/or hardware devices configured to beresponsive to determined conditions to functionally execute one or moreoperations of systems and methods herein.

Network and/or communication resources include, without limitation,local area network, wide area network, wireless, internet, or any otherknown communication resources and protocols. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers include, without limitation, a general purpose computer, aserver, an embedded computer, a mobile device, a virtual machine, and/oran emulated version of one or more of these. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers may be physical, logical, or virtual. A computer, computingdevice, processor, circuit, and/or server may be: a distributed resourceincluded as an aspect of several devices; and/or included as aninteroperable set of resources to perform described functions of thecomputer, computing device, processor, circuit, and/or server, such thatthe distributed resources function together to perform the operations ofthe computer, computing device, processor, circuit, and/or server. Incertain embodiments, each computer, computing device, processor,circuit, and/or server may be on separate hardware, and/or one or morehardware devices may include aspects of more than one computer,computing device, processor, circuit, and/or server, for example asseparately executable instructions stored on the hardware device, and/oras logically partitioned aspects of a set of executable instructions,with some aspects of the hardware device comprising a part of a firstcomputer, computing device, processor, circuit, and/or server, and someaspects of the hardware device comprising a part of a second computer,computing device, processor, circuit, and/or server.

A computer, computing device, processor, circuit, and/or server may bepart of a server, client, network infrastructure, mobile computingplatform, stationary computing platform, or other computing platform. Aprocessor may be any kind of computational or processing device capableof executing program instructions, codes, binary instructions and thelike. The processor may be or include a signal processor, digitalprocessor, embedded processor, microprocessor or any variant such as aco-processor (math co-processor, graphic co-processor, communicationco-processor and the like) and the like that may directly or indirectlyfacilitate execution of program code or program instructions storedthereon. In addition, the processor may enable execution of multipleprograms, threads, and codes. The threads may be executed simultaneouslyto enhance the performance of the processor and to facilitatesimultaneous operations of the application. By way of implementation,methods, program codes, program instructions and the like describedherein may be implemented in one or more threads. The thread may spawnother threads that may have assigned priorities associated with them;the processor may execute these threads based on priority or any otherorder based on instructions provided in the program code. The processormay include memory that stores methods, codes, instructions and programsas described herein and elsewhere. The processor may access a storagemedium through an interface that may store methods, codes, andinstructions as described herein and elsewhere. The storage mediumassociated with the processor for storing methods, programs, codes,program instructions or other type of instructions capable of beingexecuted by the computing or processing device may include but may notbe limited to one or more of a CD-ROM, DVD, memory, hard disk, flashdrive, RAM, ROM, cache and the like.

A processor may include one or more cores that may enhance speed andperformance of a multiprocessor. In embodiments, the process may be adual core processor, quad core processors, other chip-levelmultiprocessor and the like that combine two or more independent cores(called a die).

The methods and systems described herein may be deployed in part or inwhole through a machine that executes computer readable instructions ona server, client, firewall, gateway, hub, router, or other such computerand/or networking hardware. The computer readable instructions may beassociated with a server that may include a file server, print server,domain server, internet server, intranet server and other variants suchas secondary server, host server, distributed server and the like. Theserver may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other servers, clients, machines, and devices through a wiredor a wireless medium, and the like. The methods, programs, or codes asdescribed herein and elsewhere may be executed by the server. Inaddition, other devices required for execution of methods as describedin this application may be considered as a part of the infrastructureassociated with the server.

The server may provide an interface to other devices including, withoutlimitation, clients, other servers, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of instructions across the network. The networking ofsome or all of these devices may facilitate parallel processing ofprogram code, instructions, and/or programs at one or more locationswithout deviating from the scope of the disclosure. In addition, all thedevices attached to the server through an interface may include at leastone storage medium capable of storing methods, program code,instructions, and/or programs. A central repository may provide programinstructions to be executed on different devices. In thisimplementation, the remote repository may act as a storage medium formethods, program code, instructions, and/or programs.

The methods, program code, instructions, and/or programs may beassociated with a client that may include a file client, print client,domain client, internet client, intranet client and other variants suchas secondary client, host client, distributed client and the like. Theclient may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other clients, servers, machines, and devices through a wiredor a wireless medium, and the like. The methods, program code,instructions, and/or programs as described herein and elsewhere may beexecuted by the client. In addition, other devices utilized forexecution of methods as described in this application may be consideredas a part of the infrastructure associated with the client.

The client may provide an interface to other devices including, withoutlimitation, servers, other clients, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of methods, program code, instructions, and/or programsacross the network. The networking of some or all of these devices mayfacilitate parallel processing of methods, program code, instructions,and/or programs at one or more locations without deviating from thescope of the disclosure. In addition, all the devices attached to theclient through an interface may include at least one storage mediumcapable of storing methods, program code, instructions, and/or programs.A central repository may provide program instructions to be executed ondifferent devices. In this implementation, the remote repository may actas a storage medium for methods, program code, instructions, and/orprograms.

The methods and systems described herein may be deployed in part or inwhole through network infrastructures. The network infrastructure mayinclude elements such as computing devices, servers, routers, hubs,firewalls, clients, personal computers, communication devices, routingdevices and other active and passive devices, modules, and/or componentsas known in the art. The computing and/or non-computing device(s)associated with the network infrastructure may include, apart from othercomponents, a storage medium such as flash memory, buffer, stack, RAM,ROM and the like. The methods, program code, instructions, and/orprograms described herein and elsewhere may be executed by one or moreof the network infrastructural elements.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on a cellular network havingmultiple cells. The cellular network may either be frequency divisionmultiple access (FDMA) network or code division multiple access (CDMA)network. The cellular network may include mobile devices, cell sites,base stations, repeaters, antennas, towers, and the like.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on or through mobile devices.The mobile devices may include navigation devices, cell phones, mobilephones, mobile personal digital assistants, laptops, palmtops, netbooks,pagers, electronic books readers, music players, and the like. Thesemobile devices may include, apart from other components, a storagemedium such as a flash memory, buffer, RAM, ROM and one or morecomputing devices. The computing devices associated with mobile devicesmay be enabled to execute methods, program code, instructions, and/orprograms stored thereon. Alternatively, the mobile devices may beconfigured to execute instructions in collaboration with other devices.The mobile devices may communicate with base stations interfaced withservers and configured to execute methods, program code, instructions,and/or programs. The mobile devices may communicate on a peer to peernetwork, mesh network, or other communications network. The methods,program code, instructions, and/or programs may be stored on the storagemedium associated with the server and executed by a computing deviceembedded within the server. The base station may include a computingdevice and a storage medium. The storage device may store methods,program code, instructions, and/or programs executed by the computingdevices associated with the base station.

The methods, program code, instructions, and/or programs may be storedand/or accessed on machine readable transitory and/or non-transitorymedia that may include: computer components, devices, and recordingmedia that retain digital data used for computing for some interval oftime; semiconductor storage known as random access memory (RAM); massstorage typically for more permanent storage, such as optical discs,forms of magnetic storage like hard disks, tapes, drums, cards and othertypes; processor registers, cache memory, volatile memory, non-volatilememory; optical storage such as CD, DVD; removable media such as flashmemory (e.g., USB sticks or keys), floppy disks, magnetic tape, papertape, punch cards, standalone RAM disks, Zip drives, removable massstorage, off-line, and the like; other computer memory such as dynamicmemory, static memory, read/write storage, mutable storage, read only,random access, sequential access, location addressable, fileaddressable, content addressable, network attached storage, storage areanetwork, bar codes, magnetic ink, and the like.

Certain operations described herein include interpreting, receiving,and/or determining one or more values, parameters, inputs, data, orother information. Operations including interpreting, receiving, and/ordetermining any value parameter, input, data, and/or other informationinclude, without limitation: receiving data via a user input; receivingdata over a network of any type; reading a data value from a memorylocation in communication with the receiving device; utilizing a defaultvalue as a received data value; estimating, calculating, or deriving adata value based on other information available to the receiving device;and/or updating any of these in response to a later received data value.In certain embodiments, a data value may be received by a firstoperation, and later updated by a second operation, as part of thereceiving a data value. For example, when communications are down,intermittent, or interrupted, a first operation to interpret, receive,and/or determine a data value may be performed, and when communicationsare restored an updated operation to interpret, receive, and/ordetermine the data value may be performed.

Certain logical groupings of operations herein, for example methods orprocedures of the current disclosure, are provided to illustrate aspectsof the present disclosure. Operations described herein are schematicallydescribed and/or depicted, and operations may be combined, divided,re-ordered, added, or removed in a manner consistent with the disclosureherein. It is understood that the context of an operational descriptionmay require an ordering for one or more operations, and/or an order forone or more operations may be explicitly disclosed, but the order ofoperations should be understood broadly, where any equivalent groupingof operations to provide an equivalent outcome of operations isspecifically contemplated herein. For example, if a value is used in oneoperational step, the determining of the value may be required beforethat operational step in certain contexts (e.g. where the time delay ofdata for an operation to achieve a certain effect is important), but maynot be required before that operation step in other contexts (e.g. whereusage of the value from a previous execution cycle of the operationswould be sufficient for those purposes). Accordingly, in certainembodiments an order of operations and grouping of operations asdescribed is explicitly contemplated herein, and in certain embodimentsre-ordering, subdivision, and/or different grouping of operations isexplicitly contemplated herein.

The methods and systems described herein may transform physical and/oror intangible items from one state to another. The methods and systemsdescribed herein may also transform data representing physical and/orintangible items from one state to another.

The elements described and depicted herein, including in flow charts,block diagrams, and/or operational descriptions, depict and/or describespecific example arrangements of elements for purposes of illustration.However, the depicted and/or described elements, the functions thereof,and/or arrangements of these, may be implemented on machines, such asthrough computer executable transitory and/or non-transitory mediahaving a processor capable of executing program instructions storedthereon, and/or as logical circuits or hardware arrangements. Examplearrangements of programming instructions include at least: monolithicstructure of instructions; standalone modules of instructions forelements or portions thereof; and/or as modules of instructions thatemploy external routines, code, services, and so forth; and/or anycombination of these, and all such implementations are contemplated tobe within the scope of embodiments of the present disclosure Examples ofsuch machines include, without limitation, personal digital assistants,laptops, personal computers, mobile phones, other handheld computingdevices, medical equipment, wired or wireless communication devices,transducers, chips, calculators, satellites, tablet PCs, electronicbooks, gadgets, electronic devices, devices having artificialintelligence, computing devices, networking equipment, servers, routersand the like. Furthermore, the elements described and/or depictedherein, and/or any other logical components, may be implemented on amachine capable of executing program instructions. Thus, while theforegoing flow charts, block diagrams, and/or operational descriptionsset forth functional aspects of the disclosed systems, any arrangementof program instructions implementing these functional aspects arecontemplated herein. Similarly, it will be appreciated that the varioussteps identified and described above may be varied, and that the orderof steps may be adapted to particular applications of the techniquesdisclosed herein. Additionally, any steps or operations may be dividedand/or combined in any manner providing similar functionality to thedescribed operations. All such variations and modifications arecontemplated in the present disclosure. The methods and/or processesdescribed above, and steps thereof, may be implemented in hardware,program code, instructions, and/or programs or any combination ofhardware and methods, program code, instructions, and/or programssuitable for a particular application. Example hardware includes adedicated computing device or specific computing device, a particularaspect or component of a specific computing device, and/or anarrangement of hardware components and/or logical circuits to performone or more of the operations of a method and/or system. The processesmay be implemented in one or more microprocessors, microcontrollers,embedded microcontrollers, programmable digital signal processors orother programmable device, along with internal and/or external memory.The processes may also, or instead, be embodied in an applicationspecific integrated circuit, a programmable gate array, programmablearray logic, or any other device or combination of devices that may beconfigured to process electronic signals. It will further be appreciatedthat one or more of the processes may be realized as a computerexecutable code capable of being executed on a machine readable medium.

The computer executable code may be created using a structuredprogramming language such as C, an object oriented programming languagesuch as C++, or any other high-level or low-level programming language(including assembly languages, hardware description languages, anddatabase programming languages and technologies) that may be stored,compiled or interpreted to run on one of the above devices, as well asheterogeneous combinations of processors, processor architectures, orcombinations of different hardware and computer readable instructions,or any other machine capable of executing program instructions.

Thus, in one aspect, each method described above and combinationsthereof may be embodied in computer executable code that, when executingon one or more computing devices, performs the steps thereof. In anotheraspect, the methods may be embodied in systems that perform the stepsthereof, and may be distributed across devices in a number of ways, orall of the functionality may be integrated into a dedicated, standalonedevice or other hardware. In another aspect, the means for performingthe steps associated with the processes described above may include anyof the hardware and/or computer readable instructions described above.All such permutations and combinations are contemplated in embodimentsof the present disclosure.

What is claimed is:
 1. A method, comprising: providing an inspectionrobot having a payload and at least two sleds mounted to the payload;mounting a sensor on each of the at least two sleds, wherein at leastone of the sensors is an ultra-sonic (UT) sensor, wherein the UT sensoris mounted to a couplant chamber interposed between the UT sensor and aninspection surface, and the couplant chamber comprises a couplant entryfor the couplant chamber; determining a surface feature of theinspection surface; and changing a configuration of the payload bycoupling a sled lower portion replacement to an upper portion of one ofthe at least two sleds, the coupling comprising: aligning the sled lowerportion replacement with a structure of the couplant chamber thatprotrudes from the upper portion, wherein a couplant line connection atthe couplant chamber remains connected to the payload during thechanging of the configuration.
 2. The method of claim 1, whereinchanging the payload configuration comprises: selecting one of at leasttwo sled lower portion replacements in response to the surface feature;and the coupling the selected sled lower portion replacement to theupper portion of the one of the two inspection sleds, thereby forming acompleted inspection sled.
 3. The method of claim 2, wherein couplingthe selected inspection sled lower portion replacement to the upperportion further comprises twisting the inspection sled lower portionreplacement into a coupled position with the upper portion, wherein thetwisting comprises rotating the sled lower portion replacement about anaxis centered on the sensor mounted on the sled.
 4. The method of claim3, wherein the twisting further comprises rotating the sled lowerportion replacement while maintaining a same plane parallel to a bottomsurface of the sled lower portion replacement.
 5. The method of claim 3,the coupling further comprising: before the twisting, aligning anengagement slot located at a side of the sled lower portion replacementwith an engagement key located on a bottom of the upper portion; and thetwisting causing the engagement key to enter the engagement slot at theside of the sled lower portion replacement and engage the engagement keywith the engagement slot.
 6. The method of claim 3, wherein the twistingfurther comprises rotating the sled lower portion replacement about acenter axis shared by the couplant chamber and the sensor.
 7. The methodof claim 2, wherein the selecting the one of at least two sled lowerportion replacements comprises selecting a sled lower portionreplacement having at least one feature selected from the featuresconsisting of: a selected bottom surface shape; a selected ramp angle; aselected ramp total height value; a selected distance between a sensorcoupled to the upper portion and the inspection surface; and a selectedmaterial of the lower portion replacement.
 8. The method of claim 2,wherein selecting the one of the at least two sled lower portionreplacements comprises selecting a sled lower portion replacement toreplace a current worn lower portion.
 9. A system, comprising: aninspection robot comprising a plurality of payloads; a plurality ofarms, wherein each of the plurality of arms is pivotally mounted to oneof the plurality of payloads; a plurality of sleds, wherein each sled ismounted to one of the plurality of arms, wherein at least one of theplurality of sleds comprises an upper portion coupled to a replaceablelower portion, wherein the replaceable lower portion comprises a portionof a delay line for a sensor of the inspection robot; and a couplantchamber disposed within each of the plurality of sleds, wherein astructure of the couplant chamber protrudes from the upper portion ofeach of the sleds into the replaceable lower portion of each of thesleds.
 10. The system of claim 9, wherein the replaceable lower portionis selected based, at least in part, on a target length of the delayline.
 11. The system of claim 10, wherein a first subset of theplurality of arms is mounted to a first payload and a second subset ofthe plurality of arms is mounted to a second payload such that the firstsubset of the plurality of arms is horizontally offset from the secondsubset of the plurality of arms, wherein a degree of horizontal offsetdefines a horizontal inspection resolution.
 12. The system of claim 9,wherein one of the upper portion and the replaceable lower portioncomprise a plurality of engagement keys located on a bottom of the upperportion or a top of the replaceable lower portion, and wherein the otherone of the upper portion and the replaceable lower portion comprise aplurality of engagement slots located at a side of the other one of theupper portion and the replaceable lower portion.
 13. The system of claim9, wherein the replaceable lower portion further comprises a rampcharacteristic, and wherein the ramp characteristic is selected in parton an inspection surface.
 14. The system of claim 13, wherein the rampcharacteristic comprises a bottom surface contour selected to match inpart an inspection surface contour.
 15. A method comprising: providingan inspection robot having a payload and a first plurality of sleds eachcoupled to the payload via a respective plurality of arms on thepayload, and each sled having a ramp portion; and changing the payloadto a second payload and a second plurality of sleds each coupled to thesecond payload, each sled of the second plurality of sleds having a rampportion, wherein each sled of the first plurality of sleds and thesecond plurality of sleds comprises a sensor mounted thereon, eachsensor mounted to a couplant chamber interposed between a correspondingsensor and an inspection surface, and each couplant chamber comprising acouplant entry for the couplant chamber, wherein changing the payloaddoes not include disconnecting a couplant line connection at thecouplant chamber, and wherein the changing the payload compriseschanging a horizontal distribution of sleds for the inspection robot byconfiguring a position of the plurality of arms on the payload.
 16. Themethod of claim 15, further comprising performing an inspectionoperation of the inspection surface with the inspection robot.
 17. Themethod of claim 16, wherein changing the horizontal distribution ofsleds for the inspection robot defines an inspection resolution for theinspection operation.
 18. The method of claim 17, wherein changing thepayload further comprises providing the second plurality of sleds havinga bottom surface contoured in response to a shape of the inspectionsurface.
 19. The method of claim 15, wherein the ramp portion of thesecond plurality of sleds comprises a second ramp characteristic that isdistinct from a first ramp characteristic of the ramp portion of thefirst plurality of sleds.
 20. The method of claim 19, wherein the secondramp characteristic comprises at least one distinction selected from thedistinctions consisting of a ramp angle or a ramp height.
 21. The methodof claim 19, wherein the second ramp characteristic comprises a changein delay line.
 22. The method of claim 15, wherein the configuring theposition of the plurality of arms on the payload comprises adjusting adistance between the plurality of arms on the payload.